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At least 217 records · Page 12

Meshing of a Spiral Bevel Gearset with 3D Finite Element Analysis

Recent advances in spiral bevel gear geometry and finite element technology make it practical to conduct a structural analysis and analytically roll the gearset through mesh. With the advent of user specific programming linked to 3D solid modelers and mesh generators, model generation has become greatly automated. Contact algorithms available in general purpose finite element codes eliminate the need for the use and alignment of gap elements. Once the gearset is placed in mesh, user subroutines attached to the FE code easily roll the gearset through mesh. The method is described in detail. Preliminary results for a gearset segment showing the progression of the contact lineload is given as the gears roll through mesh.

Bibel, George D.↗

A meshing framework for digital twins for extrusion based additive manufacturing

Additive manufacturing (AM) allows for manufacturing of complex three-dimensional geometries not typically realizable with standard manufacturing practices. The internal microstructure of AM components has a significant impact on mechanical, vibrational, and shock properties and permits richer design space when this is controllable. Due to complex interactions of internal geometry of an extrusion-based AM component, it is common practice to assume homogeneous behavior or to perform characterization testing on specific toolpath configurations. To avoid testing or material waste, it is necessary to develop a consistently accurate numerical simulation framework with relevant boundary value problems that can handle the complicated geometry of internal material microstructure present in AM components. Herein, a framework is proposed to directly create computational meshes suitable for finite element analysis (FEA) of the fine-scale features generated from extrusion-based AM tool paths to maintain a strong process–structure–property-performance linkage. This mesh can be manually or automatically analyzed using standard FEA simulations such as quasi-static preloading or modal analysis. The framework allows an in-silico assessment of a target AM geometry where fine-scale features greatly impact quantities of design interest such as in soft elastomeric lattices where toolpath infill can greatly influence the self-contact of a structure in compression, which we use as a motivating exemplar. This approach greatly reduces both time and resource waste present in traditional build and test design cycles for non-intuitive design spaces, and acts as a tool for use in the production of a key component of a digital twin, a mesh suitable for finite element analysis. In conclusion, it also further allows for the exploration of toolpath infill to optimize component properties beyond simple linear properties such as density and stiffness.

Additive manufacturing↗

Extrusion of Complex Surface Meshes Utilizing Face Offsetting and Mean Curvature Smoothing

Grids for three-dimensional Computational Fluid Dynamics problems frequently require a prismatic layer of cells, typically extruded in the off-body direction from a two-dimensional surface mesh to properly resolve boundary layers. When the surface geometry is complex, the extrusion process can fail, resulting in the physical boundary layer being thicker than the prismatic layer, leading to under-resolved boundary layers. To address the shortcomings of existing grid generation tools, a new tool has been developed as part of the Mesh Tools suite, that is capable of extruding complex surface meshes. The new tool uses a face offsetting method to preserve surface curvature and a mean curvature smoothing algorithm to prevent the cells from self-intersecting in concave regions. Testing of the new tool found that not only were complex surface meshes able to be extruded to the desired thickness, but extrusion of simple surface meshes was also improved, due to the face offsetting method.

mesh extrusion↗

Recent Development in the CESE Method for the Solution of the Navier-Stokes Equations Using Unstructured Triangular or Tetrahedral Meshes With High Aspect Ratio

In the multidimensional CESE development, triangles and tetrahedra turn out to be the most natural building blocks for 2D and 3D spatial meshes. As such the CESE method is compatible with the simplest unstructured meshes and thus can be easily applied to solve problems with complex geometries. However, because the method uses space-time staggered stencils, solution decoupling may become a real nuisance in applications involving unstructured meshes. In this paper we will describe a simple and general remedy which, according to numerical experiments, has removed any possibility of solution decoupling. Moreover, in a real-world viscous flow simulation near a solid wall, one often encounters a case where a boundary with high curvature or sharp corner is surrounded by triangular/tetrahedral meshes of extremely high aspect ratio (up to 106). For such an extreme case, the spatial projection of a space-time compounded conservation element constructed using the original CESE design may become highly concave and thus its centroid (referred to as a spatial solution point) may lie far outside of the spatial projection. It could even be embedded beyond a solid wall boundary and causes serious numerical difficulties. In this paper we will also present a new procedure for constructing conservation elements and solution elements which effectively overcomes the difficulties associated with the original design. Another difficulty issue which was addressed more recently is the wellknown fact that accuracy of gradient computations involving triangular/tetrahedral grids deteriorates rapidly as the aspect ratio of grid cells increases. The root cause of this difficulty was clearly identified and several remedies to overcome it were found through a rigorous mathematical analysis. However, because of the length of the current paper and the complexity of mathematics involved, this new work will be presented in another paper.

Chang, Sin-Chung↗

Unit cell geometry of multiaxial preforms for structural composites

The objective of this study is to investigate the yarn geometry of multiaxial preforms. The importance of multiaxial preforms for structural composites is well recognized by the industry but, to exploit their full potential, engineering design rules must be established. This study is a step in that direction. In this work the preform geometry for knitted and braided preforms was studied by making a range of well designed samples and studying them by photo microscopy. The structural geometry of the preforms is related to the processing parameters. Based on solid modeling and B-spline methodology a software package is developed. This computer code enables real time structural representations of complex fiber architecture based on the rule of preform manufacturing. The code has the capability of zooming and section plotting. These capabilities provide a powerful means to study the effect of processing variables on the preform geometry. the code also can be extended to an auto mesh generator for downstream structural analysis using finite element method. This report is organized into six sections. In the first section the scope and background of this work is elaborated. In section two the unit cell geometries of braided and multi-axial warp knitted preforms is discussed. The theoretical frame work of yarn path modeling and solid modeling is presented in section three. The thin section microscopy carried out to observe the structural geometry of the preforms is the subject in section four. The structural geometry is related to the processing parameters in section five. Section six documents the implementation of the modeling techniques into the computer code MP-CAD. A user manual for the software is also presented here. The source codes and published papers are listed in the Appendices.

Ko, Frank↗

Adjoint Algorithm for CAD-Based Shape Optimization Using a Cartesian Method

Adjoint solutions of the governing flow equations are becoming increasingly important for the development of efficient analysis and optimization algorithms. A well-known use of the adjoint method is gradient-based shape optimization. Given an objective function that defines some measure of performance, such as the lift and drag functionals, its gradient is computed at a cost that is essentially independent of the number of design variables (geometric parameters that control the shape). More recently, emerging adjoint applications focus on the analysis problem, where the adjoint solution is used to drive mesh adaptation, as well as to provide estimates of functional error bounds and corrections. The attractive feature of this approach is that the mesh-adaptation procedure targets a specific functional, thereby localizing the mesh refinement and reducing computational cost. Our focus is on the development of adjoint-based optimization techniques for a Cartesian method with embedded boundaries.12 In contrast t o implementations on structured and unstructured grids, Cartesian methods decouple the surface discretization from the volume mesh. This feature makes Cartesian methods well suited for the automated analysis of complex geometry problems, and consequently a promising approach to aerodynamic optimization. Melvin et developed an adjoint formulation for the TRANAIR code, which is based on the full-potential equation with viscous corrections. More recently, Dadone and Grossman presented an adjoint formulation for the Euler equations. In both approaches, a boundary condition is introduced to approximate the effects of the evolving surface shape that results in accurate gradient computation. Central to automated shape optimization algorithms is the issue of geometry modeling and control. The need to optimize complex, "real-life" geometry provides a strong incentive for the use of parametric-CAD systems within the optimization procedure. In previous work, we presented an effective optimization framework that incorporates a direct-CAD interface. In this work, we enhance the capabilities of this framework with efficient gradient computations using the discrete adjoint method. We present details of the adjoint numerical implementation, which reuses the domain decomposition, multigrid, and time-marching schemes of the flow solver. Furthermore, we explain and demonstrate the use of CAD in conjunction with the Cartesian adjoint approach. The final paper will contain a number of complex geometry, industrially relevant examples with many design variables to demonstrate the effectiveness of the adjoint method on Cartesian meshes.

Nemec, Marian↗

Data transfers for full core heterogeneous reactor high- fidelity multiphysics studies

Multiphysics simulations for nuclear reactor analysis are usually performed by resorting to operator splitting and fixed point iterations between single-physics solvers. This enables the separate solution of each physics, such as neutronics, fuel performance, and thermal hydraulics, on meshes tailored to the requirements of the respective numerical discretizations of the equations. As the equations are coupled, several fields must be transferred between single-physics solves. Projecting fields between meshes while preserving order of accuracy, conservation properties, and mapping non-overlapping geometries is a complex endeavor. This conference paper will present the transfers as implemented in MOOSE, which can handle arbitrary meshes, arbitrary mappings, conservation of integral quantities, and are made to scale with distributed simulations on both ends of the transfers. Their adequacy for advanced nuclear reactor multiphysics coupling is shown through examples and numerical studies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Adaptive Mesh Refinement for Microelectronic Device Design

Finite element and finite volume methods are used in a variety of design simulations when it is necessary to compute fields throughout regions that contain varying materials or geometry. Convergence of the simulation can be assessed by uniformly increasing the mesh density until an observable quantity stabilizes. Depending on the electrical size of the problem, uniform refinement of the mesh may be computationally infeasible due to memory limitations. Similarly, depending on the geometric complexity of the object being modeled, uniform refinement can be inefficient since regions that do not need refinement add to the computational expense. In either case, convergence to the correct (measured) solution is not guaranteed. Adaptive mesh refinement methods attempt to selectively refine the region of the mesh that is estimated to contain proportionally higher solution errors. The refinement may be obtained by decreasing the element size (h-refinement), by increasing the order of the element (p-refinement) or by a combination of the two (h-p refinement). A successful adaptive strategy refines the mesh to produce an accurate solution measured against the correct fields without undue computational expense. This is accomplished by the use of a) reliable a posteriori error estimates, b) hierarchal elements, and c) automatic adaptive mesh generation. Adaptive methods are also useful when problems with multi-scale field variations are encountered. These occur in active electronic devices that have thin doped layers and also when mixed physics is used in the calculation. The mesh needs to be fine at and near the thin layer to capture rapid field or charge variations, but can coarsen away from these layers where field variations smoothen and charge densities are uniform. This poster will present an adaptive mesh refinement package that runs on parallel computers and is applied to specific microelectronic device simulations. Passive sensors that operate in the infrared portion of the spectrum as well as active device simulations that model charge transport and Maxwell's equations will be presented.

Cwik, Tom↗

Multigrid acceleration of a fractional-step solver in generalized curvilinear coordinate systems

The efficiency of the INS3D-fractional step (FS) code has been significantly enhanced by accelerating the Poisson solver with a multigrid (MG) method. This is apparently the first implementation of the MG method for solving the 3D discrete Poisson-like equation obtained in the derivation of FS solution methods for the incompressible Navier-Stokes equations in generalized nonorthogonal coordinate systems using a staggered arrangement of the variables. The MG solver is insensitive to the geometry, even in cases of highly nonorthogonal clustered meshes, as well as to the free parameters of MG methods.

Rosenfeld, Moshe↗

Inlet Spillage Drag Predictions Using the AIRPLANE Code

AIRPLANE (Jameson/Baker) is a steady inviscid unstructured Euler flow solver. It has been validated on many HSR geometries. It is implemented as MESHPLANE, an unstructured mesh generator, and FLOPLANE, an iterative flow solver. The surface description from an Intergraph CAD system goes into MESHPLANE as collections of polygonal curves to generate the 3D mesh. The flow solver uses a multistage time stepping scheme with residual averaging to approach steady state, but R is not time accurate. The flow solver was ported from Cray to IBM SP2 by Wu-Sun Cheng (IBM); it could only be run on 4 CPUs at a time because of memory limitations. Meshes for the four cases had about 655,000 points in the flow field, about 3.9 million tetrahedra, about 77,500 points on the surface. The flow solver took about 23 wall seconds per iteration when using 4 CPUs. It took about eight and a half wall hours to run 1,300 iterations at a time (the queue limit is 10 hours). A revised version of FLOPLANE (Thomas) was used on up to 64 CPUs to finish up some calculations at the end. We had to turn on more communication when using more processors to eliminate noise that was contaminating the flow field; this added about 50% to the elapsed wall time per iteration when using 64 CPUs. This study involved computing lift and drag for a wing/body/nacelle configuration at Mach 0.9 and 4 degrees pitch. Four cases were considered, corresponding to four nacelle mass flow conditions.

Thomas, Scott D.↗

IFCPT S-Duct Grid-Adapted FUN3D Computations for the Third Propulsion Aerodynamics Works

Contributions of the unstructured Reynolds-averaged Navier-Stokes code, FUN3D, to the 3rd AIAA Propulsion Aerodynamics Workshop are described for the diffusing IFCPT S-Duct. Using workshop-supplied grids, results for the baseline S-Duct, baseline S-Duct with Aerodynamic Interface Plane (AIP) rake hardware, and baseline S-Duct with flow control devices are compared with experimental data and results computed with output-based, off-body grid adaptation in FUN3D. Due to the absence of influential geometry components, total pressure recovery is overpredicted on the baseline S-Duct and S-Duct with flow control vanes when compared to experimental values. An estimate for the exact value of total pressure recovery is derived for these cases given an infinitely refined mesh. When results from output-based mesh adaptation are compared with those computed on workshop-supplied grids, a considerable improvement in predicting total pressure recovery is observed. By including more representative geometry, output-based mesh adaptation compares very favorably with experimental data in terms of predicting the total pressure recovery cost-function; whereas, results computed using the workshop-supplied grids are underpredicted.

Davis, Zach S.↗

Hydrologic Model Data for the East Fork Poplar Creek Watershed Simulated with the Advanced Terrestrial Simulator (ATS): Streamflow and Network Expansion–Contraction Dynamics

This dataset supports hydrologic modeling and stream network expansion–contraction analysis for the East Fork Poplar Creek (EFPC) Watershed in Tennessee. It includes a Jupyter notebook for model setup, model configuration files, simulation outputs, and derived products used to evaluate model performance and investigate stream dynamics under varying hydrologic conditions. The dataset was generated using the Watershed Workflow Python package and the Advanced Terrestrial Simulator (ATS), enabling integrated surface–subsurface hydrologic simulations using a stream-aligned mesh. Outputs include high-resolution time series of streamflow, active network length, water table depth, and related hydrologic variables. Also included are spatially explicit stream persistency indices and classifications of reaches as perennial or non-perennial. These data facilitate reproducibility and support further research on stream intermittency and variability in network extent.The model data archive is organized in following directories:1) model_setup_inputsContains the Watershed Workflow Jupyter notebooks (accessed through any open source code editor), selected input datasets, and resulting ATS input files, including XML files (access through any open source code editor), computational mesh (.exo files can be viewed using Paraview), and meteorological forcing files (.h5 files can be accessed through h5py python package and HDFView open source software). 2) model_outputsIncludes ATS simulation outputs relevant to this study. Time series of spatially integrated or averaged variables (e.g., streamflow, water table depth) are provided as CSV files. Select spatial fields (e.g., ponded depth and water table depth) are saved as pickled Python objects to reduce file size, and can be accessed through pickle package in Python. Key geometry objects from Watershed Workflow—such as the surface mesh and river tree—are also included to support analysis of streamflow persistency and expansion–contraction dynamics. These files can also be accessed through Watershed Workflow Python package.3) model_evaluationProvides observed streamflow time series and field survey-based flow regime classifications used to evaluate model performance. Jupyter notebooks for processing ATS outputs and comparing model predictions with observations to build confidence in the model prior to scientific analysis are also included.4) Q_L_relationshipsContains workflows for generating time series of discharge, active network length, and related hydrologic variables used in the stream network expansion–contraction analysis. Includes routines for delineating baseflow-dominated periods. For each catchment, notebooks and processed data (as pickled DataFrames accessed through Pandas Python package) are provided. 5) figure_scriptsProvides the Jupyter notebooks used to generate the figures presented in the paper.

54 ENVIRONMENTAL SCIENCES↗

A FORTRAN program for calculating three dimensional, inviscid and rotational flows with shock waves in axial compressor blade rows: User's manual

A FORTRAN-IV computer program was developed for the calculation of the inviscid transonic/supersonic flow field in a fully three dimensional blade passage of an axial compressor rotor or stator. Rotors may have dampers (part span shrouds). MacCormack's explicit time marching method is used to solve the unsteady Euler equations on a finite difference mesh. This technique captures shocks and smears them over several grid points. Input quantities are blade row geometry, operating conditions and thermodynamic quanities. Output quantities are three velocity components, density and internal energy at each mesh point. Other flow quanities are calculated from these variables. A short graphics package is included with the code, and may be used to display the finite difference grid, blade geometry and static pressure contour plots on blade to blade calculation surfaces or blade suction and pressure surfaces. The flow in a low aspect ratio transonic compressor was analyzed and compared with high response total pressure probe measurements and gas fluorescence static density measurements made in the MIT blowdown wind tunnel. These comparisons show that the computed flow fields accurately model the measured shock wave locations and overall aerodynamic performance.

Thompkins, W. T., Jr.↗

TetCrust WILD: Weighted Delaunay meshing in the wild

We introduce the first conforming Voronoi mesher capable of handling unclean input geometries encountered 'in the wild'. Our algorithm handles non-watertight, non-manifold, and self-intersecting inputs without requiring any manual cleanup, providing a standalone, end-to-end meshing framework. The framework enables simultaneous Voronoi and weighted Delaunay meshing, allowing users to generate polyhedral or tetrahedral elements based on application requirements, and produces high-quality elements

Ebeida, Mohamed Salah [Sandia National Laboratorie↗

Monte Carlo Simulation with CAD Interface for Calculation of 3D Maps of Residual Dose (CRADA)

Objective: To develop an easy-to-use software application to predict and mitigate radiation effects in research environment, space instruments, nuclear plants and medical facilities and help nonproliferation and national security efforts. Tech-X will develop standalone software libraries and command-line tools for ( 1) translating CAD into tessellated surfaces and tetrahedral meshes in GDML (for Geant4 and MARS 15), ROOT (for MARS 15) and HDF5 (for compact representation and for the visualization) formats, (2) healing CAD geometries to make them suitable for Monte Carlo simulations; (3) creating uniform and variable Cartesian and cylindrical meshes for detailed scoring; and ( 4) efficient Monte Carlo navigation in CAD geometries. JLAB will finish automation of simulations of residual dose in CAD geometries and integrate Tech-X software into Geant4 and MARS15. Finally, Tech-X will develop a Graphical User Interface to set up and heal CAD geometries, create input files, run and visualize simulations for residual dose. This application will run on local desktops, local and remote clusters and supercomputers and will be made available through public clouds, such as Amazon Web Services.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Rapid particle generation from an STL file and related issues in the application of material point methods to complex objects

Abstract In this paper, we focus on three issues related to applications of material point methods (MPMs) to objects with complex geometries. They are material point generation, compatibility of material points with a mesh, and sensitivity to mesh orientation. An efficient method of generating material points from a stereolithography (STL) file is introduced. This material point generation method is independent of the mesh used in MPM calculations. The compatibility between the material points and the mesh is then studied. We also show that the original MPM and the dual domain material point (DDMP) method are sensitive to mesh orientation. These issues are related to the calculation of the internal force and are concerns of the MPMs. They become more prominent when MPMs are applied to complex geometries. Our numerical results show that the recently developed local stress difference (LSD) algorithm (Perez et al. in J Comp Phys 498:112681, 2024) can be used to effectively address them.

36 MATERIALS SCIENCE↗

EchemAMR (electro-chemical microsctructure scale models with adaptive meshing) [SWR-23-111]

A 3D microstructure resolving electrochemical transport and interfacial chemistry solver. Electrode microstructure plays an important role in determining the performance of an electrochemical system, e.g. lithium ion battery. EchemAMR is a microstructure scale model that solves the governing equations for ion transport, electrical current continuity, interfacial chemistry and structural mechanics. Complex microstructure geometries from imaging can be directly imported into EchemAMR. A volume fraction based description of the geometry on Cartesian grid with an immersed interface formulation enables simplified meshing and large-scale simulations with millions of degrees of freedom. EchemAMR has been tested against systems with analytic solutions for numerical convergence and highly resolved lithium ion battery microstructures. EchemAMR demonstrates excellent mass conversation and efficient scaling on heterogenous High-Performance Computing (HPC) with central and graphics processing units.

Sitaraman, Hariswaran↗

Automated Generation of Finite-Element Meshes for Aircraft Conceptual Design

This paper presents a novel approach for automated generation of fully connected finite-element meshes for all internal structural components and skins of a given wing-body geometry model, controlled by a few conceptual-level structural layout parameters. Internal structural components include spars, ribs, frames, and bulkheads. Structural layout parameters include spar/rib locations in wing chordwise/spanwise direction and frame/bulkhead locations in longitudinal direction. A simple shell thickness optimization problem with two load conditions is used to verify versatility and robustness of the automated meshing process. The automation process is implemented in ModelCenter starting from an OpenVSP geometry and ending with a NASTRAN 200 solution. One subsonic configuration and one supersonic configuration are used for numerical verification. Two different structural layouts are constructed for each configuration and five finite-element meshes of different sizes are generated for each layout. The paper includes various comparisons of solutions of 20 thickness optimization problems, as well as discussions on how the optimal solutions are affected by the stress constraint bound and the initial guess of design variables.

Li, Wu↗