Impact Modeling with Explicit Eulerian to Explicit Lagrangian Coupling Using the Modified Immersed Finite Element Method
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Thomas, Jesse David [Sandia National Laboratories ↗
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Enriched immersed finite element and isogeometric analysis: algorithms and data structures
Immersed finite element methods provide a convenient analysis framework for problems involving geometrically complex domains, such as those found in topology optimization and microstructures for engineered materials. However, their implementation remains a major challenge due to, among other things, the need to apply nontrivial stabilization schemes and generate custom quadrature rules. This article introduces the robust and computationally efficient algorithms and data structures comprising an immersed finite element preprocessing framework. The input to the preprocessor consists of a background mesh and one or more geometries defined on its domain. The output is structured into groups of elements with custom quadrature rules formatted such that common finite element assembly routines may be used without or with only minimal modifications. The key to the preprocessing framework is the construction of material topology information, concurrently with the generation of a quadrature rule, which is then used to perform enrichment and generate stabilization rules. While the algorithmic framework applies to a wide range of immersed finite element methods using different types of meshes, integration, and stabilization schemes, the preprocessor is presented within the context of the extended isogeometric analysis. This method utilizes a structured B-spline mesh, a generalized Heaviside enrichment strategy considering the material layout within individual basis functions’ supports, and face-oriented ghost stabilization. Using a set of examples, the effectiveness of the enrichment and stabilization strategies is demonstrated alongside the preprocessor’s robustness in geometric edge cases. Additionally, the performance and parallel scalability of the implementation are evaluated.
Computer implementation↗
Adaptive immersed isogeometric level-set topology optimization
Here, this paper presents for the first time an adaptive immersed approach for level-set topology optimization using higher-order truncated hierarchical B-spline discretizations for design and state variable fields. Boundaries and interfaces are represented implicitly by the iso-contour of one or multiple level-set functions. An immersed finite element method, the eXtended IsoGeometric Analysis, is used to predict the physical response. The proposed optimization framework affords different adaptively refined higher-order B-spline discretizations for individual design and state variable fields. The increased continuity of higher-order B-spline discretizations together with local refinement enables direct control over the accuracy of the representation of each field while simultaneously reducing computational cost compared to uniformly refined discretizations. A flexible mesh adaptation strategy enables local refinement based on geometric measures or physics-based error indicators. These adaptive discretization and analysis approaches are integrated into gradient-based optimization schemes, evaluating the design sensitivities using the adjoint method. Numerical studies illustrate the features of the proposed framework with static, linear elastic, multi-material, two- and three-dimensional problems. The examples provide insight into the effect of refining the design variable field on the optimization result and the convergence rate of the optimization process. Using coarse higher-order B-spline discretizations for level-set fields promotes the development of smooth designs and suppresses the emergence of small features. Moreover, adaptive mesh refinement for state variable fields results in a reduction of overall computational cost. Higher-order B-spline discretizations are especially interesting when evaluating gradients of state variable fields due to their higher inter-element continuity.
36 MATERIALS SCIENCE↗
Analysis of the weighted shifted boundary method for the Poisson and Stokes problems
The Shifted Boundary Method (SBM) belongs to the class of unfitted (or immersed, or embedded) finite element methods, and relies on reformulating the original boundary value problem over a surrogate (approximate) computational domain. Accuracy is maintained by properly shifting the location and values of the boundary conditions. This avoids integration over cut cells and the associated implementation issues. Recently, the Weighted SBM (WSBM) was proposed for the Navier-Stokes equations with free surfaces and the Stokes flow with moving boundaries. The attribute “weighted” in the name WSBM stems from the fact that its variational form is weighted with the elemental volume fraction of active fluid. The motivation for the development of the WSBM was the preservation of the volume of active fluid to a higher degree of accuracy, which in turn resulted in improved stability and robustness characteristics in moving-boundary, time-dependent simulations. In this article, we present the numerical analysis of the WSBM formulations for the Poisson and Stokes problems. We give mathematical conditions under which the bilinear forms defining the discrete variational formulations are uniformly coercive (Poisson problem) or inf-sup stable (Stokes problem). By these results, stability and optimal convergence is proven in the natural norm; L2-error estimates can also be derived.
Approximate domain boundaries↗
Fluid-Structure Interaction Simulations of the ASPIRE SR01 Supersonic Parachute
High-fidelity computational fluid dynamics (CFD) simulations have so far only played exploratory and supporting roles in the study and qualification of parachutes for planetary entry. The last few years have seen the maturation of coupled computational methods that are capable of modeling the complex fluid-structure interactions between a parachute canopy and the supersonic flow in the wake of an entry vehicle in flight conditions. One of the primary goals of these methods is to predict the peak opening load experienced by the parachute during inflation. The Launch, Ascent, and Vehicle Aerodynamics (LAVA)team is developing efficient, high-fidelity numerical methods to perform such challenging fluid-structure interaction simulations. A loose coupling approach is used to advance the solutions of a Cartesian ghost cell immersed boundary method CFD solver and a finite element computational structural dynamics (CSD) solver in space and time. The coupled solver is employed to simulate the ASPIRE SR01 flight test, where a build-to-print version of the Mars Science Laboratory parachute was inflated in supersonic conditions in the upper terrestrial atmosphere. The simulations conducted in the current paper predict a peak opening load that is within 10% of that from the flight test. Grid convergence with respect to the volume and structural domains is demonstrated, and less than 1% variation in the peak opening load is predicted between all grid resolutions.
ARMD↗
Solving Fluid Structure Interaction Problems with an Immersed Boundary Method
An immersed boundary method for the compressible Navier-Stokes equations can be used for moving boundary problems as well as fully coupled fluid-structure interaction is presented. The underlying Cartesian immersed boundary method of the Launch Ascent and Vehicle Aerodynamics (LAVA) framework, based on the locally stabilized immersed boundary method previously presented by the authors, is extended to account for unsteady boundary motion and coupled to linear and geometrically nonlinear structural finite element solvers. The approach is validated for moving boundary problems with prescribed body motion and fully coupled fluid structure interaction problems. Keywords: Immersed Boundary Method, Higher-Order Finite Difference Method, Fluid Structure Interaction.
Structure Interactions↗
A numerical comparison with an exact solution for the transient response of a cylinder immersed in a fluid
The transient response of an elastic cylindrical shell immersed in an acoustic media that is engulfed by a plane wave is determined numerically. The method applies to the USA-STAGS code which utilizes the finite element method for the structural analysis and the doubly asymptotic approximation for the fluid-structure interaction. The calculations are compared to an exact analysis for two separate loading cases: a plane step wave and an exponentially decaying plane wave.
Giltrud, M. E.↗
An Immersed Boundary Method for Solving the Compressible Navier-Stokes Equations with Fluid Structure Interaction
An immersed boundary method for the compressible Navier-Stokes equation and the additional infrastructure that is needed to solve moving boundary problems and fully coupled fluid-structure interaction is described. All the methods described in this paper were implemented in NASA's LAVA solver framework. The underlying immersed boundary method is based on the locally stabilized immersed boundary method that was previously introduced by the authors. In the present paper this method is extended to account for all aspects that are involved for fluid structure interaction simulations, such as fast geometry queries and stencil computations, the treatment of freshly cleared cells, and the coupling of the computational fluid dynamics solver with a linear structural finite element method. The current approach is validated for moving boundary problems with prescribed body motion and fully coupled fluid structure interaction problems in 2D and 3D. As part of the validation procedure, results from the second AIAA aeroelastic prediction workshop are also presented. The current paper is regarded as a proof of concept study, while more advanced methods for fluid structure interaction are currently being investigated, such as geometric and material nonlinearities, and advanced coupling approaches.
Equations↗
Simulation of Physical Experiments in Immersive Virtual Environments
An object-oriented event-driven immersive Virtual environment is described for the creation of virtual labs (VLs) for simulating physical experiments. Discussion focuses on a number of aspects of the VLs, including interface devices, software objects, and various applications. The VLs interface with output devices, including immersive stereoscopic screed(s) and stereo speakers; and a variety of input devices, including body tracking (head and hands), haptic gloves, wand, joystick, mouse, microphone, and keyboard. The VL incorporates the following types of primitive software objects: interface objects, support objects, geometric entities, and finite elements. Each object encapsulates a set of properties, methods, and events that define its behavior, appearance, and functions. A container object allows grouping of several objects. Applications of the VLs include viewing the results of the physical experiment, viewing a computer simulation of the physical experiment, simulation of the experiments procedure, computational steering, and remote control of the physical experiment. In addition, the VL can be used as a risk-free (safe) environment for training. The implementation of virtual structures testing machines, virtual wind tunnels, and a virtual acoustic testing facility is described.
Noor, Ahmed K.↗
Ultrasonic Nondestructive Characterization of Adhesive Bonds
Qualitative measurements of adhesion or binding forces can be accomplished, for example, by using the reflection coefficient of an ultrasound or by using thermal waves (Light and Kwun, 1989, Achenbach and Parikh, 1991, and Bostrom and wickham, 1991). However, a quantitative determination of binding forces is rather difficult. It has been observed that higher harmonics of the fundamental frequency are generated when an ultrasound passes through a nonlinear material. It seems that such non-linearity can be effectively used to characterize the bond strength. Several theories have been developed to model this nonlinear effect (Adler and Nagy, 1991; Achenbach and Parikh, 1991; Parikh and Achenbach, 1992; and Hirose and Kitahara, 1992; Anastasi and Roberts, 1992). Based on a microscopic description of the nonlinear interface binding force, a quantitative method was presented by Pangraz and Arnold (1994). Recently, Tang, Cheng and Achenbach (1997) made a comparison between the experimental and simulated results based on this theoretical model. A water immersion mode-converted shear wave through-transmission setup was used by Berndt and Green (1997) to analyze the nonlinear acoustic behavior of the adhesive bond. In this project, the nonlinear responses of an adhesive joint was investigated through transmission tests of ultrasonic wave and analyzed by the finite element simulations. The higher order harmonics were obtained in the tests. It is found that the amplitude of higher harmonics increases as the aging increases, especially the 3dorder harmonics. Results from the numerical simulation show that the material nonlinearity does indeed generate higher order harmonics. In particular, the elastic-perfect plastic behavior generates significant 3rd and 5th order harmonics.
Qu, Jianmin↗
A Posteriori Bounds for Linear-Functional Outputs of Crouzeix-Raviart Finite Element Discretizations of the Incompressible Stokes Problem
We present a finite element technique for the efficient generation of lower and upper bounds to outputs which are linear functionals of the solutions to the incompressible Stokes equations in two space dimensions; the finite element discretization is effected by Crouzeix-Raviart elements, the discontinuous pressure approximation of which is central to our approach. The bounds are based upon the construction of an augmented Lagrangian: the objective is a quadratic "energy" reformulation of the desired output; the constraints are the finite element equilibrium equations (including the incompressibility constraint), and the intersubdomain continuity conditions on velocity. Appeal to the dual max-min problem for appropriately chosen candidate Lagrange multipliers then yields inexpensive bounds for the output associated with a fine-mesh discretization; the Lagrange multipliers are generated by exploiting an associated coarse-mesh approximation. In addition to the requisite coarse-mesh calculations, the bound technique requires solution only of local subdomain Stokes problems on the fine-mesh. The method is illustrated for the Stokes equations, in which the outputs of interest are the flowrate past, and the lift force on, a body immersed in a channel.
Patera, Anthony T.↗
Resolution of the buoyancy in the 8-foot high temperature tunnel combustor
Currently, the 8-Foot High Temperature Tunnel (8-Ft. HTT) combustor produces a good profile at only one point (2000 psia and 3650 R with oxygen enrichment). Air is enriched with oxygen (liquid) so that the combustor product gas will contain the volumetric amount of oxygen normally found in air. The oxygen enriched air has a large fraction that is not reacted and flows through the outer periphery of the fuel injector. This ring of cold air in addition to the relatively cold walls of the combustor set up buoyancy forces that produce a segregation of relatively cool gases at the bottom of the combustor exit. The basic problem is to produce a test gas that has uniform properties at all combustor conditions. The combustor temperature may be as high as 3700 R or as low as 2000 R. Combustor pressures can be as high as 3500 psia (no oxygen enrichment) and as low as 600 psia. The segregation is most severe with oxygen enriched air, since its temperature is lower and its density is high. The combustor is lined with nickel 201 and can be operated at about 1600 R maximum. A global mixing process is desired that produces an acceptable profile of temperature, species, and velocity at the exit of the combustor. The ultimate goal is a temperature profile with about 100 R variance and about 2 percent variance in oxygen. The exit total temperature must not be lowered significantly by the mixing apparatus or mechanisms employed. If immersed bodies are used, they must also be kept very hot. All combustor wall modifications must be able to survive the heat and structural conditions of the varied operating conditions. Our approach to resolving this issue is being conducted in three stages: (1) Consider mixing exclusively, (2) Resolve the heat transfer concerns resulting from the chosen mixing strategy, and (3) Solve the material and structural problems resulting from stages (1) and (2). Since the 8-Ft. HTT is unavailable for experimentation, the study is conducted exclusively with computational fluid dynamic (CPD) codes (Fluent/Uns and Rampant 3.1) using unstructured grid through body fitted coordinates. Both CFD codes are general purpose Navier-Stokes solution packages that can solve integral conservation equations for conservation of mass, momentum and energy. The governing equations are discretized using a control-volume finite-element method on unstructured triangular 2-D grids. In the interest of time, a 3-D tetrahedral grid was used to check the 2-D results on one mixing strategy and the 2-D results were confirmed. Preliminary results indicate that excellent mixing can be achieved with a body placed in the center of the flowing hot fluid with a minor modification to the combustor wall similar to a model positioned in the test section of a wind tunnel. The concept here, is to create longitudinal vortices strong enough to bring both fluids into intimate contact with each other near the wall where the cold fluid resides. However, there may be a trade-off in the choice of mixing strategy, heat transfer and structural requirements. Currently, we are examining the more promising geometries for heat transfer concerns and developing strategies for the material of construction of the center body.
Loney, Norman W.↗
Finite Element Methods for real-time Haptic Feedback of Soft-Tissue Models in Virtual Reality Simulators
We have applied the linear elastic finite element method to compute haptic force feedback and domain deformations of soft tissue models for use in virtual reality simulators. Our results show that, for virtual object models of high-resolution 3D data (>10,000 nodes), haptic real time computations (>500 Hz) are not currently possible using traditional methods. Current research efforts are focused in the following areas: 1) efficient implementation of fully adaptive multi-resolution methods and 2) multi-resolution methods with specialized basis functions to capture the singularity at the haptic interface (point loading). To achieve real time computations, we propose parallel processing of a Jacobi preconditioned conjugate gradient method applied to a reduced system of equations resulting from surface domain decomposition. This can effectively be achieved using reconfigurable computing systems such as field programmable gate arrays (FPGA), thereby providing a flexible solution that allows for new FPGA implementations as improved algorithms become available. The resulting soft tissue simulation system would meet NASA Virtual Glovebox requirements and, at the same time, provide a generalized simulation engine for any immersive environment application, such as biomedical/surgical procedures or interactive scientific applications.
Frank, Andreas O.↗
High-Speed and High-Quality Field Welding Repair Based on Advanced Non-Destructive Evaluation and Numerical Modeling
Creep strength-enhanced ferritic (CSEF) steels such as Grade 91 (9Cr-1Mo-V) and Grade 92 (Fe-9Cr-2W-0.5Mo) steels are widely used in the fossil-fuel-fired and nuclear power plants. The weld integrity of these steels is crucial for power plants' safe and reliable operations. Due to harsh service conditions, the steel weld can become susceptible to environmental degradation. Field welding repair is used to restore the degraded weld’s performance where a controlled temper-bead welding technique is commonly used to temper the freshly formed martensite during welding. However, knowledge of weld repairability is limited and experimental trial and error optimization to achieve desired microstructure and joint properties is expensive and time-consuming. Many existing computational models, e.g., finite element models, are limited to solving heat conduction equation and ignoring convective heat transfer due to molten metal flow. These models can result in over-prediction of peak temperatures of weld pool and heat-affected zone (HAZ), which in turn can affect the accuracy of tempering prediction. Moreover, these finite element models require an input of the deposit profiles in advance and thus limits the usability of these models. Here, a molten pool-based, multi-pass multi-layer model has been developed based on computational fluid dynamics (CFD) approach with the Volume of Fluid (VOF) method. The model calculates the bead formation, thereby eliminating the need for pre-determined bead profiles required by finite element models. For computational efficiency, a coordinate system attached to the moving heat source is utilized. A subroutine is developed to convert the temperature profiles in the reference frame stationary to the heat source to that stationary to the workpiece. The converted thermal cycles are then imported into a microstructure model to compute the tempering kinetics and resultant hardness using a Johnson-Mehl-Avrami-Kolmogorov (JMAK), and modified Grange-Baughman parameter. The modeling approach is first developed and validated on single- and multi-pass deposition of stainless steel filler metal onto a SA-533 high strength steel substrate. The models are then applied to a multi-pass V-groove repair weld of Grade 91 steel plate as well as directed energy deposition of Grade 92 steel. Non-destructive characterization of microstructures was performed on Grade 91 and 92 steel welds. Two welding processes, cold metal transfer (CMT) and flux-cored arc welding (FCAW), were investigated for the Grade 91 steel weld samples. For the Grade 92 weld samples, three different heat inputs (low, medium, and high) of gas tungsten arc welding (GTAW) were utilized to replicate traditional field welding processes. The non-destructive evaluation (NDE) method used for this research was immersion ultrasonic testing (UT) using a micro-resolution ultrasonic imaging methodology specifically designed to operate in the through-transmission configuration operating at 20 MHz of frequency. The system used a focused ultrasonic beam spot size diameter between 250-300 μm, and a 6 μm laser vibrometer spot size for detection, to produce highly defined images with longitudinal and mode-converted shear waves. From the micro-resolution ultrasonic C-scan images, three microstructural regions, i.e., weld metal (WM), HAZ, and base metal (BM), were clearly identifiable. Various levels of ultrasonic amplitudes distributed over the three regions were correlated with electron beam backscattered diffraction (EBSD) images using grain size, grain boundaries, and dislocation densities. The results showed that areas with relatively higher ultrasonic amplitude levels were associated with smaller grains and higher dislocation densities, while areas with lower amplitude levels were associated with larger grains and lower dislocation densities. In addition, ultrasonic velocity data obtained across the three different weld microstructural regions of Grade 91 test samples were correlated with optical metallographic images and hardness measurements. The results showed distinctive decreases in ultrasonic velocity and hardness over the HAZ region, where weld failures often occur during service.
36 MATERIALS SCIENCE↗
Ultrasonic Nondestructive Evaluation Techniques Applied to the Quantitative Characterization of Textile Composite Materials
In this Progress Report, we describe our recent developments of advanced ultrasonic nondestructive evaluation methods applied to the characterization of anisotropic materials. We present images obtained from experimental measurements of ultrasonic diffraction patterns for a thin woven composite in an immersion setup. In addition, we compare apparent signal loss measurements of the thin woven composite for phase-sensitive and phase-insensitive detection methods. All images of diffraction patterns have been included on the accompanying CD-ROM in the Adobe(Trademark) Portable Document Format (PDF). Due to the extensive amount of data, however, hardcopies of only a small representative selection of the images are included within the printed report. This Progress Report presents experimental results that support successful implementation of single element as well as one and two-dimensional ultrasonic array technologies for the inspection of textile composite structures. In our previous reports, we have addressed issues regarding beam profiles of ultrasonic pressure fields transmitted through a water reference path and transmitted through a thin woven composite sample path. Furthermore, we presented experimental results of the effect of a thin woven composite on the magnitude of an insonifying ultrasonic pressure field. In addition to the study of ultrasonic beam profiles, we consider issues relevant to the application of single-element, one-dimensional, and two-dimensional array technologies towards probing the mechanical properties of advanced engineering composites and structures. We provide comparisons between phase-sensitive and phase-insensitive detection methods for determination of textile composite structure parameters. We also compare phase-sensitive and phase-insensitive - - ---- ----- apparent signal loss measurements in an effort to study the phenomenon of phase cancellation at the face of a finite-aperture single-element receiver. Furthermore, in this Progress Report we extend our work on ultrasonic beam profile issues through investigation of the phase fronts of the pressure field. In Section H of this Progress Report we briefly describe the experimental arrangement and methods for data acquisition of the ultrasonic diffraction patterns upon transmission through a thin woven composite. Section III details the analysis of the experimental data followed by the experimental results in Section IV. Finally, a discussion of the observations and conclusions is found in Section V.
Miller, James G.↗