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Full-Field Reconstruction of Structural Deformations and Loads from Measured Strain Data on a Wing Using the Inverse Finite Element Method

A study was undertaken to investigate the measurement of wing deformation and internal loads using measured strain data. Future aerospace vehicle research depends on the ability to accurately measure the deformation and internal loads during ground testing and in flight. The approach uses the inverse Finite Element Method (iFEM). The iFEM is a robust, computationally efficient method that is well suited for real-time measurement of real-time structural deformation and loads. The method has been validated in previous work, but has yet to be applied to a large-scale test article. This work is in preparation for an upcoming loads test of a half-span test wing in the Flight Loads Laboratory at the National Aeronautics and Space Administration Armstrong Flight Research Center (Edwards, California). The method has been implemented into an efficient MATLAB® (The MathWorks, Inc., Natick, Massachusetts) code for testing different sensor configurations. This report discusses formulation and implementation along with the preliminary results from a representative aerospace structure. The end goal is to investigate the modeling and sensor placement approach so that the best practices can be applied to future aerospace projects.

Finite element

Finite element method for non-linear forced vibrations of circular plates

Geometric non-linearities for large amplitude free and forced vibrations of circular plates are investigated. In-plane displacement and in-plane inertia are included in the formulation. The finite element method is used. An harmonic force matrix for non-linear forced vibration analysis is introduced and derived. Various out-of-plane and in-plane boundary conditions are considered. The relations of amplitude and frequency ratio for different boundary conditions and various load conditions are presented.

Mei, Chuh

A finite element method for the thermochemical decomposition of polymeric materials. I - Theory

The governing differential equations are developed to model the thermomechanical behavior of chemically decomposing, polymeric materials. These equations account for thermal and gaseous diffusion through a poroelastic, transversely isotropic solid. The Bubnov-Galerkin finite element method is applied to the governing equations to cast the coupled set into a single matrix equation. A method for solving these equations simultaneously at each time step is discussed.

Sullivan, R. M.

A Finite Element Method for Compressible and Turbulent Multiphase Flow Instabilities with Heat Transfer

We present a new finite element framework for modeling compressible, turbulent multiphase flows with heat transfer. For two-fluid systems with a free surface, the Volume of Fluid (VOF) method is implemented without the need for interface reconstruction, while turbulence is resolved using a dynamic Vreman large eddy simulation (LES) model. Unlike most two-phase VOF studies, which neglect heat transfer, the present approach incorporates energy transport equations within the VOF formulation to account for heat exchange, an effect particularly important in turbulent flows. Conjugate heat transfer is often challenging in finite volume methods, which require explicit specification of heat fluxes at the solid–fluid interface, limiting accuracy and predictive capability. By contrast, the finite element formulation does not require heat flux inputs, allowing more accurate and robust simulation of heat transfer between solids and fluids. The method is demonstrated through three representative cases. First, a two-fluid instability with a single-mode perturbation is simulated and validated against analytical growth rates. Second, conjugate heat transfer is examined in a high-temperature flow over a cold metal cylinder, with validation performed both quantitatively—via pressure coefficient comparisons with experimental data—and qualitatively using vector field topology. Finally, compressible spray injection and breakup are modeled, demonstrating the ability of the framework to capture interfacial dynamics and atomization under turbulent, high-speed conditions. In the compressible spray injection and breakup case, the results indicate that the finite element formulation achieved higher predictive accuracy and robustness than the finite-volume method. With the same mesh resolution, the FEM reduced the root mean square error (RMSE) and mean absolute percentage error (MAPE) from 6.96 mm and 26.0% (for the FVM) to 4.85 mm and 12.7%, respectively, demonstrating improved accuracy and robustness in capturing interfacial dynamics and heat transfer. The study also introduced vector field topology to visualize and interpret coherent flow structures and instabilities, offering insights beyond conventional scalar-field analyses.

97 MATHEMATICS AND COMPUTING

An efficient finite element method for aircraft de-icing problems

In this paper, a finite element formulation based on an assumed states method is proposed for the solution of heat conduction problems with phase change at a fixed temperature. Attention is directed toward reduction of computer cost through the use of an efficient formulation, solver and algorithm. The procedure is applied to the analysis of an electrothermally deiced aircraft surface.

Huang, J. R.

Shape and Stress Sensing of Multilayered Composite and Sandwich Structures Using an Inverse Finite Element Method

The marked increase in the use of composite and sandwich material systems in aerospace, civil, and marine structures leads to the need for integrated Structural Health Management systems. A key capability to enable such systems is the real-time reconstruction of structural deformations, stresses, and failure criteria that are inferred from in-situ, discrete-location strain measurements. This technology is commonly referred to as shape- and stress-sensing. Presented herein is a computationally efficient shape- and stress-sensing methodology that is ideally suited for applications to laminated composite and sandwich structures. The new approach employs the inverse Finite Element Method (iFEM) as a general framework and the Refined Zigzag Theory (RZT) as the underlying plate theory. A three-node inverse plate finite element is formulated. The element formulation enables robust and efficient modeling of plate structures instrumented with strain sensors that have arbitrary positions. The methodology leads to a set of linear algebraic equations that are solved efficiently for the unknown nodal displacements. These displacements are then used at the finite element level to compute full-field strains, stresses, and failure criteria that are in turn used to assess structural integrity. Numerical results for multilayered, highly heterogeneous laminates demonstrate the unique capability of this new formulation for shape- and stress-sensing.

Cerracchio, Priscilla

Scattering and radiation analysis of three-dimensional cavity arrays via a hybrid finite element method

A hybrid numerical technique is presented for a characterization of the scattering and radiation properties of three-dimensional cavity arrays recessed in a ground plane. The technique combines the finite element and boundary integral methods and invokes Floquet's representation to formulate a system of equations for the fields at the apertures and those inside the cavities. The system is solved via the conjugate gradient method in conjunction with the Fast Fourier Transform (FFT) thus achieving an O(N) storage requirement. By virtue of the finite element method, the proposed technique is applicable to periodic arrays comprised of cavities having arbitrary shape and filled with inhomogeneous dielectrics. Several numerical results are presented, along with new measured data, which demonstrate the validity, efficiency, and capability of the technique.

Jin, Jian-Ming

A Statistical Approach for the Concurrent Coupling of Molecular Dynamics and Finite Element Methods

Molecular dynamics (MD) methods are opening new opportunities for simulating the fundamental processes of material behavior at the atomistic level. However, increasing the size of the MD domain quickly presents intractable computational demands. A robust approach to surmount this computational limitation has been to unite continuum modeling procedures such as the finite element method (FEM) with MD analyses thereby reducing the region of atomic scale refinement. The challenging problem is to seamlessly connect the two inherently different simulation techniques at their interface. In the present work, a new approach to MD-FEM coupling is developed based on a restatement of the typical boundary value problem used to define a coupled domain. The method uses statistical averaging of the atomistic MD domain to provide displacement interface boundary conditions to the surrounding continuum FEM region, which, in return, generates interface reaction forces applied as piecewise constant traction boundary conditions to the MD domain. The two systems are computationally disconnected and communicate only through a continuous update of their boundary conditions. With the use of statistical averages of the atomistic quantities to couple the two computational schemes, the developed approach is referred to as an embedded statistical coupling method (ESCM) as opposed to a direct coupling method where interface atoms and FEM nodes are individually related. The methodology is inherently applicable to three-dimensional domains, avoids discretization of the continuum model down to atomic scales, and permits arbitrary temperatures to be applied.

Saether, E.

A finite element method for diffusion dominated unsteady viscous flows

A general conforming finite element scheme for computing viscous flows is presented which is of second-order accuracy in space and time. Viscous terms are treated implicitly and advection terms are treated explicitly in the time marching segment of the algorithm. A method for solving the algebraic equations at each time step is given. The method is demonstrated on two test problems, one of them being a plane vortex flow for which asymptotic methods are used to obtain suitable numerical boundary conditions at each time step.

Gunzburger, M. D.

Finite element methods for integrated aerodynamic heating analysis

Over the past few years finite element based procedures for the solution of high speed viscous compressible flows were developed. The objective of this research is to build upon the finite element concepts which have already been demonstrated and to develop these ideas to produce a method which is applicable to the solution of large scale practical problems. The problems of interest range from three dimensional full vehicle Euler simulations to local analysis of three-dimensional viscous laminar flow. Transient Euler flow simulations involving moving bodies are also to be included. An important feature of the research is to be the coupling of the flow solution methods with thermal/structural modeling techniques to provide an integrated fluid/thermal/structural modeling capability. The progress made towards achieving these goals during the first twelve month period of the research is presented.

Peraire, J.

A compact finite element method for elastic bodies

A nonconforming finite method is described for treating linear equilibrium problems, and a convergence proof showing second order accuracy is given. The close relationship to a related compact finite difference scheme due to Phillips and Rose is examined. A condensation technique is shown to preserve the compactness property and suggests an approach to a certain type of homogenization.

Rose, M. E.

Developing Procedures to Implement Geometric Imperfections Beyond Right Circular Cylindrical Shells in Finite Element Method Models

Analysis of aerospace structures is frequently conducted using nominal dimensions and frequently assumes ideal conditions in loading, contact, constraints, et cetera. Off-nominal dimensions and nonideal conditions, however, are present in all structures. These are the result of widely ranging causes from coefficient of thermal expansion mismatches, manufacturing tooling anomalies, to assembly procedures that inadvertently alter the structure. Specifically, geometric imperfections can have potentially significant influence on the response of a structural test article observed in an experiment versus the response given by a numerical simulation. The Python Tool for Implementing Geometric Imperfections in Reduced Structures (Py_TIGIRS) was previously presented as a set of Python scripts to calculate and implement as-manufactured geometric midsurface and thickness imperfections into finite element method (FEM) shell models of nominally right circular cylinders. By taking advantage of the simple shape of a right circular cylinder, interpolations of the measured data points were able to be performed along directions that aligned to the cylindrical coordinate system axes of the entire structure. By taking advantage of the shell representation of the real structure as opposed to modeling using a continuum representation, the thickness variation was able to be implemented by shell section definitions instead of having to modify the position of multiple nodes in the thickness direction. Py_TIGIRS is a useful tool that established a procedural example on how to implement geometric imperfections in right circular cylindrical shell structures. Three new procedures, each expanded from concepts established in Py_TIGIRS, are proposed for various test-article designs and are intended to broaden the range of structures that can be modeled with measured geometric imperfections in the structural analysis community. Each test-article design introduces new challenges to successfully implement geometric imperfections into a FEM model. The first test-article design consists of a carbon fiber reinforced polymer square plate with a hat-shaped stiffener co-cured on one side. This test-article design was for a novel seven-point bend test that was also previously presented. Manufacturing and cure-cycle imperfections are observed using digital image correlation (DIC) techniques. As thermal expansion coefficient mismatches between the plate and stiffener materials were anticipated, a thermal analysis study with continuum shell and solid elements was conducted to capture the global shape observed prior to testing. The second test-article design is of a similar hat-stiffened plate configuration, but with a side length ratio near 3:1 with elongation in the stiffener direction. The test article was used to characterize the response to uniaxial compressive loading in the direction of the stiffener. Due to differing manufacturing steps, a thermal analysis like the one developed for the seven-point bend configuration was unable to mimic the observed geometric imperfections. Instead, a strategy based on applying deformations directly to the structure during analysis was developed for continuum shell and solid element representation of a stiffened panel.

Geometric imperfections

Analysis and Development of Finite Element Methods for the Study of Nonlinear Thermomechanical Behavior of Structural Components

Underintegrated methods are investigated with respect to their stability and convergence properties. The focus was on identifying regions where they work and regions where techniques such as hourglass viscosity and hourglass control can be used. Results obtained show that underintegrated methods typically lead to finite element stiffness with spurious modes in the solution. However, problems exist (scalar elliptic boundary value problems) where underintegrated with hourglass control yield convergent solutions. Also, stress averaging in underintegrated stiffness calculations does not necessarily lead to stable or convergent stress states.

Oden, J. Tinsley

Finite Element Method for Thermal Analysis

A two- and three-dimensional, finite-element thermal-analysis program which handles conduction with internal heat generation, convection, radiation, specified flux, and specified temperature boundary conditions is presented. Elements used in the program are the triangle and tetrahedron for two- and three-dimensional analysis, respectively. The theory used in the program is developed, and several sample problems demonstrating the capability and reliability of the program are presented. A guide to using the program, description of the input cards, and program listing are included.

Heuser, J.

A finite element method for nonlinear forced vibrations of beams

Techniques for defining a finite element model (FEM) for analysis of nonlinear vibrations in beam structures subjected to harmonic excitation are presented. The resulting model covers longitudinal deformation and inertial effects. The nonlinear oscillations of a beam element under forced excitation are modeled by a harmonic force matrix based on first order approximations of the Jacobian elliptic forcing function. Harmonic force and nonlinear stiffness matrices are derived and the nonlinear forced responses of beams are calculated under various boundary conditions. The results of FEM computations for simply-supported and clamped beams show that midplane stretching caused by large deflections increases the nonlinearity. Axially-restrained beams experience only hardening nonlinearity, while axially-free beams have reduced nonlinearity in deformation and inertia and an increase in linearity due to large deflection.

Mei, C.

Simulation of Two-Fluid Flows by the Least-Squares Finite Element Method Using a Continuum Surface Tension Model

In this paper a numerical procedure for simulating two-fluid flows is presented. This procedure is based on the Volume of Fluid (VOF) method proposed by Hirt and Nichols and the continuum surface force (CSF) model developed by Brackbill, et al. In the VOF method fluids of different properties are identified through the use of a continuous field variable (color function). The color function assigns a unique constant (color) to each fluid. The interfaces between different fluids are distinct due to sharp gradients of the color function. The evolution of the interfaces is captured by solving the convective equation of the color function. The CSF model is used as a means to treat surface tension effect at the interfaces. Here a modified version of the CSF model, proposed by Jacqmin, is used to calculate the tension force. In the modified version, the force term is obtained by calculating the divergence of a stress tensor defined by the gradient of the color function. In its analytical form, this stress formulation is equivalent to the original CSF model. Numerically, however, the use of the stress formulation has some advantages over the original CSF model, as it bypasses the difficulty in approximating the curvatures of the interfaces. The least-squares finite element method (LSFEM) is used to discretize the governing equation systems. The LSFEM has proven to be effective in solving incompressible Navier-Stokes equations and pure convection equations, making it an ideal candidate for the present applications. The LSFEM handles all the equations in a unified manner without any additional special treatment such as upwinding or artificial dissipation. Various bench mark tests have been carried out for both two dimensional planar and axisymmetric flows, including a dam breaking, oscillating and stationary bubbles and a conical liquid sheet in a pressure swirl atomizer.

Wu, Jie

Multi-material ALE remap with interface sharpening using high-order matrix-free finite element methods

The arbitrary Lagrangian-Eulerian (ALE) technique involves remapping field quantities from a Lagrangian mesh to an optimized mesh in a conservative, accurate and bounds-preserving manner. For methods based on arbitrary order finite elements, as described in a reference, material volume fractions are advected in pseudo-time using flux-corrected transport (FCT) without any form of interface reconstruction. In practice, this can lead to excessive propagation of small volume fractions throughout the domain. In addition, this method requires assembly of a global advection matrix to compute the bounds-preserving low-order FCT solution. In this work, we introduce a new approach for ALE remap using a high-order matrix-free technique which incorporates a flux modification to sharpen material interfaces in a conservative manner. Our approach begins with computing a bounds-preserving low-order solution to the ALE remap equations at the element level. We then compute a sharp interface solution (not guaranteed to be bounds-preserving) which comes from solving an augmented version of the ALE remap equations with a conservative flux modification which acts to sharpen material volume fractions based on their gradients and transport directions. Using the sharp interface solution, we make global corrections to the bounds-preserving solution while maintaining preservation of bounds. By blending with the sharpened solution at the global level we are able to globally conserve mass without hindering the remap pseudo-time step. This new interface-aware ALE remap method is based entirely on partial assembly techniques where globally assembled matrix operators are no longer needed, resulting in a globally matrix-free FCT method for multi-material, multi-field ALE remap with high performance on GPU architectures. We present results of our new remap method on 1D, 2D and 3D benchmarks and describe the algorithmic tailoring for GPU architectures that was developed.

Vargas, Arturo [Lawrence Livermore National Labora