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NASA NTRSDate not supplied

Advances in Automation of Overset Structured Volume Mesh Generation and Domain Connectivity

Automation of overset structured surface mesh generation has recently been accomplished by the creation of face, edge, and node meshes based on Boundary Representation solids as the geometry input. The current work continues the automation effort in overset volume mesh generation and domain connectivity based on the auto-generated surface meshes. All near-body curvilinear volume meshes are automatically generated using hyperbolic methods. Automation of this step is enabled by appropriate surface grid point distribution, and selection of boundary-splay and smoothing parameters based on concave and convex surface features. The off-body domain is covered by two automatically generated grid systems. The first contains a single Cartesian mesh with a uniform core enclosing all near-body volume meshes and stretched layers that extend to the far field, while the second consists of a set of small stretched Cartesian grids covering pockets of off-body orphan points. With high quality mesh overlap mostly guaranteed by the surface meshing scheme, orphan points that need to be covered by the second Cartesian mesh system are located away from the fine grid spacing region near the wall. Using line-segment and ray-pierce tests against the surface grids, hole-cutting is accomplished on both near and off-body volume grids resulting in appropriate clearances from the wall. The complete mesh generation automation process is demonstrated on five test cases where flow solutions are also computed and compared with solutions obtained using other methods.

TTT↗

DOE OSTI2019

A dual mesh method with adaptivity for stress-constrained topology optimization

This paper is concerned with the topological optimization of elastic structures, with the goal of minimizing the compliance and/or mass of the structure, subject to a stress constraint. It is well known that depending upon the geometry and the loading conditions, the stress field can exhibit singularities, if these singularities are not adequately resolved, the topological optimization process will be ineffective. For computational efficiency, adaptive mesh refinement is required to adequately resolve the stress field. This poses a challenge for the traditional Solid Isotropic Material with Penalization (SIMP) method that employs a one-to-one correspondence between the finite element mesh and the optimization design variables because as the mesh is refined, the optimization process must somehow be re-started with a new set of design variables. The proposed solution here is a dual mesh approach, one finite element mesh defines the material distribution, a second finite element mesh is used for the computation of the displacement and stress fields. This allows for stress-based adaptive mesh refinement without modifying the definition of the optimization design variables. A second benefit of this dual mesh approach is that there is no need to apply a filter to the design variables to enforce a length scale, instead the length scale is determined by the design mesh. This reduces the number of design variables and allows the designer to apply spatially varying length scale if desired. The efficacy of this dual mesh approach is established via several stress-constrained topology optimization problems.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Simulation-driven optimization of high-order meshes in ALE hydrodynamics

Here we propose tools for high-order mesh optimization and demonstrate their benefits in the context of multi-material Arbitrary Lagrangian-Eulerian (ALE) compressible shock hydrodynamic applications. The mesh optimization process is driven by information provided by the simulation which uses the optimized mesh, such as shock positions, material regions, known error estimates, etc. These simulation features are usually represented discretely, for instance, as finite element functions on the Lagrangian mesh. The discrete nature of the input is critical for the practical applicability of the algorithms we propose and distinguishes this work from approaches that strictly require analytical information. Our methods are based on node movement through a high-order extension of the Target-Matrix Optimization Paradigm (TMOP). The proposed formulation is fully algebraic and relies only on local Jacobian matrices, so it is applicable to all types of mesh elements, in 2D and 3D, and any order of the mesh. We discuss the notions of constructing adaptive target matrices and obtaining their derivatives, reconstructing discrete data in intermediate meshes, node limiting that enables improvement of global mesh quality while preserving space-dependent local mesh features, and appropriate normalization of the objective function. The adaptivity methods are combined with automatic ALE triggers that can provide robustness of the mesh evolution and avoid excessive remap procedures. The benefits of the new high-order TMOP technology are illustrated on several simulations performed in the high-order ALE application BLAST.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

3D mesh regularization within an ALE code using a weighted line sweeping method

The Lagrangian formalism is widely used to simulate hydrodynamic responses in complex engineering applications, particularly those involving strong shock waves. However, as the mesh moves with the fluid, it can become highly distorted, requiring a regularization step. This involves constructing a new grid and remapping conservative quantities onto it to restore mesh quality. This work introduces a regularization method for block-structured meshes within a 3D ALE (Arbitrary Lagrangian-Eulerian) code. The proposed approach prevents mesh tangling while preserving the anisotropic features of the initial Lagrangian mesh. This regularization technique incorporates aspect ratio-based weights to control mesh smoothing. Unlike uniform rezoning techniques, this weighted approach maintains proximity to the Lagrangian mesh while improving mesh quality. Here, the method effectively handles concave geometries by mitigating the grid attraction phenomenon, which typically leads to mesh concentration along concave edges. Numerical experiments demonstrate its efficiency in regularizing severely deformed meshes, and its integration within the ALE framework is validated on challenging hydrodynamic test cases, including the triple point problem.

42 ENGINEERING↗

DOE OSTI2022

Physics demonstration and verification of MOOSE framework reactor module meshing capabilities

The recently developed Reactor module in the open-source MOOSE framework includes finite element meshing capabilities for analysis of common reactor geometries. Capabilities in the Reactor module have been employed to generate meshes for physics applications including a sodium-cooled fast reactor core analysis using Griffin, a fast reactor assembly thermal deformation analysis using MOOSE Tensor Mechanics, and a heat-pipe cooled microreactor coupled analysis using Griffin, Bison, and Sockeye. The process to build these meshes using MOOSE's meshing capabilities is described. Physics simulation results using MOOSE-based meshes have been verified to match results which leverage external meshing software such as Cubit or Argonne's Mesh Tools. MOOSE's Reactor module provides significant advantages compared to the use of external meshing tools when analyzing Cartesian and hexagonal reactor lattices using MOOSE-based applications: accessibility to the end user, low barrier to entry for new users, speed of mesh generation, volume preservation of meshed fuel pins, and simplification of analysis workflow when using MOOSE applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Deploy production sliding mesh capability with linear solver benchmarking.

Wind applications require the ability to simulate rotating blades. To support this use-case, a novel design-order sliding mesh algorithm has been developed and deployed. The hybrid method combines the control volume finite element methodology (CVFEM) with concepts found within a discontinuous Galerkin (DG) finite element method (FEM) to manage a sliding mesh. The method has been demonstrated to be design-order for the tested polynomial basis (P=1 and P=2) and has been deployed to provide production simulation capability for a Vestas V27 (225 kW) wind turbine. Other stationary and canonical rotating ow simulations are also presented. As the majority of wind-energy applications are driving extensive usage of hybrid meshes, a foundational study that outlines near-wall numerical behavior for a variety of element topologies is presented. Results indicate that the proposed nonlinear stabilization operator (NSO) is an effective stabilization methodology to control Gibbs phenomena at large cell Peclet numbers. The study also provides practical mesh resolution guidelines for future analysis efforts. Application-driven performance and algorithmic improvements have been carried out to increase robustness of the scheme on hybrid production wind energy meshes. Specifically, the Kokkos-based Nalu Kernel construct outlined in the FY17/Q4 ExaWind milestone has been transitioned to the hybrid mesh regime. This code base is exercised within a full V27 production run. Simulation timings for parallel search and custom ghosting are presented. As the low-Mach application space requires implicit matrix solves, the cost of matrix reinitialization has been evaluated on a variety of production meshes. Results indicate that at low element counts, i.e., fewer than 100 million elements, matrix graph initialization and preconditioner setup times are small. However, as mesh sizes increase, e.g., 500 million elements, simulation time associated with \setup-up" costs can increase to nearly 50% of overall simulation time when using the full Tpetra solver stack and nearly 35% when using a mixed Tpetra- Hypre-based solver stack. The report also highlights the project achievement of surpassing the 1 billion element mesh scale for a production V27 hybrid mesh. A detailed timing breakdown is presented that again suggests work to be done in the setup events associated with the linear system. In order to mitigate these initialization costs, several application paths have been explored, all of which are designed to reduce the frequency of matrix reinitialization. Methods such as removing Jacobian entries on the dynamic matrix columns (in concert with increased inner equation iterations), and lagging of Jacobian entries have reduced setup times at the cost of numerical stability. Artificially increasing, or bloating, the matrix stencil to ensure that full Jacobians are included is developed with results suggesting that this methodology is useful in decreasing reinitialization events without loss of matrix contributions. With the above foundational advances in computational capability, the project is well positioned to begin scientific inquiry on a variety of wind-farm physics such as turbine/turbine wake interactions.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

CrossLink: Advancements in Scalable Unstructured Mesh Generation [Slides]

Traditional mesh generation approaches are labor intensive and have limited robustness when applied to parametric design exploration and optimization of complex geometries. While automatic mesh generation approaches exist, they tend to generate tetrahedral or mixed-hybrid meshes which are generally unsuitable for physics applications with strong shock waves, thin boundary layers, and strong gradients. In addition, simulations sizes in the billions of cells are becoming more common with traditional mesh generation methods quickly reaching scalability limits. CrossLink offers a topology-based mesh generation approach with unstructured block-filling methods and a scalable mesh generation engine. In addition, CrossLink incorporates a python based API for seamless workflow integration and robust repeatability of the geometry handling and mesh generation process. This makes it ideal for parametric design study and optimization of complex geometries. Finally, future versions of CrossLink will offer a parametric mesh capability that optimizes a high-order mesh and enables reconstruction of the final mesh in memory by the physics solver.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

High-Order Mesh hr-adaptivity for Surface Fitting to Implicit Geometries

We present an ℎ𝑟-adaptivity framework for morphing a given mesh to fit a target surface prescribed as the zero isocontour of a discrete function. In this framework, high-order meshing is posed as a variational minimization problem that depends on the mesh quality prescribed via the target matrix optimization paradigm (TMOP) and position of a subset of mesh nodes with respect to the target surface. The proposed formulation ensures that the variational problem is converged and mesh quality degradation near the surface is limited, even when the mesh topology is incompatible with the target surface. Additionally, a mesh subset-based approach and ℎ-refinement is introduced to efficiently increase fitting accuracy while reducing the computational cost of the mesh morphing problem. The ℎ𝑟-adaptivity technique extends to different element types in two- and three-dimensions, and can be used in existing finite element and spectral element frameworks to obtain high-order body-fitted meshes. Various numerical experiments demonstrate the robustness and accuracy of the fitting approach for problems of practical interest such as Lagrangian hydrodynamics and topology optimization.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Variable-fidelity multipoint aerodynamic shape optimization with output-based adapted meshes

This work presents a method to control the discretization error in multipoint aerodynamic shape optimization using output-based adapted meshes. The meshes are adapted via adjoint-based error estimates, taking into account both the objective and constraint output errors. A multi-fidelity optimization framework is then developed by taking advantage of the variable fidelity offered by adaptive meshes. The objective functional and its sensitivity at each design point (operating condition) are first evaluated on the same initial coarse mesh, which is then subsequently adapted for each design point individually as the shape optimization proceeds. The effort to set up the optimization is minimal since the initial mesh can be fairly coarse and easy to generate. As the shape approaches the optimal design, the mesh at each design point becomes finer, in regions necessary for that particular operating condition. The multi-fidelity framework is tightly coupled with the objective error estimation to ensure the optimization accuracy at each fidelity. Computational savings arise from a reduction of the mesh size when the design is far from optimal and avoiding an exhaustive search on low-fidelity meshes. The proposed method is demonstrated on multipoint drag minimization problems of a transonic airfoil with lift and area constraints. Improved accuracy and efficiency are shown compared to traditional fixed-fidelity optimization with a fixed computational mesh.

42 ENGINEERING↗

DOE OSTI2023

MOOSE Reactor Module: An Open-Source Capability for Meshing Nuclear Reactor Geometries

The U.S. Department of Energy (DOE) Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has developed numerous physics solvers utilizing the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE) framework for multiphysics reactor analysis. These solvers require input finite element meshes representing the discretized spatial domain. Typically, reactor analysts turn to licensed tools for the creation of reactor geometry meshes. Recently, open-source functionality has been added to the MOOSE framework to mesh common reactor geometries and improve MOOSE-based nuclear reactor application user workflows. The new functionality is primarily contained in the new Reactor module of MOOSE and includes support for hexagonal pins, assemblies, and cores, extended Cartesian geometry support, options for modeling static and rotating control drums within a hexagonal assembly, core periphery triangulation, and automatic tagging of pin, assembly, plane, and depletion regions for easier post processing of physics results. A set of reactor geometry mesh builder objects further streamlines the construction of hexagonal and Cartesian cores and allows mapping of materials to regions during mesh generation. The meshes produced with the MOOSE Reactor module may be used directly within MOOSE-based applications or exported as Exodus II files for use in other finite element solvers. The tools have been demonstrated and verified using a variety of NEAMS physics solvers on a range of reactor applications, including a sodium-cooled fast reactor core analysis using Griffin, a fast reactor assembly thermal deformation analysis using MOOSE Tensor Mechanics, and a heat pipe–cooled microreactor coupled analysis using Griffin, Bison, and Sockeye. MOOSE’s Reactor module provides significant advantages compared to the use of external meshing tools when analyzing Cartesian and hexagonal reactor lattices using MOOSE-based applications: immediate accessibility (open-source) to the end user, low barrier to entry for new users, speed of mesh generation, volume preservation of meshed fuel pins, and simplification of analysis workflow when used in conjunction with MOOSE-based applications.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

NucMesh: nuclear reactor geometry creation and mesh generation module in NEMoSys

NucMesh is a parameterized geometry and mesh generator for nuclear reactors developed within the Nuclear Energy Modeling System NEMoSys at Illinois Rocstar. NEMoSys is a platform developed for mesh generation, adaptive refinement, and solution verification. NucMesh is implemented to be generalized and extensible with a robust computer aided design engine and multiple mesh generation algorithms for unstructured triangular, quad-dominant, and structured quadrilateral meshing. In this paper, we present the geometric and meshing features of NucMesh. Geometrically objects are constructed bottom-to-top and overlaps are addressed automatically. A sophisticated object tracking algorithm prevents data from being lost for segmented objects. We discuss the primitive objects of circle and polygons that constitute the module and show how they are used with example inputs. Arrays of primitives and arrays of arrays are utilized to build large assemblies of objects. The concept of saved objects is discussed to demonstrate how repetitive objects can be reused easily and augmented in place. Three dimensional meshes can be obtained through mesh extrusion where all materials and side sets are extended to three dimensions. We show that side sets can be defined nearly anywhere within the geometry and can then be applied to the mesh. Finally, example reactor meshes are demonstrated for the Idaho National Laboratory Advanced Test Reactor and Los Alamos National Lab Empire reactor, both of which use control drums that NucMesh handles easily. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRSDate not supplied

Comparing Unstructured Adaptive Mesh Solutions for the High Lift Common Research Model Airfoil

Discretization error is a common source of uncertainty in Computational Fluid Dynamics (CFD) analyses. Traditional means of controlling discretization error through fixed-mesh refinement studies has proven to be difficult particularly when modeling complex geometries and flow fields. One reason for this is that mesh generation in today’s production CFD workflow is often a labor intensive process that is heavily dependent on user judgment. Unstructured mesh adaptation is known to be an efficient way to control discretization errors in CFD. Adaptive methods replace user based decision making with automated processes that optimize a mesh to reduce discretization error. This paper compares the application of multiple solution adaptive techniques in combination with multiple flow solvers to solve for the flow field about a 2D airfoil section of the NASA High-Lift Common Research Model (HL-CRM). By driving the adaptive mesh processes to a similar level of mesh convergence, the ability to achieve consistent results between multiple adaptive techniques and flow solvers is demonstrated. Mesh convergence for the various adaptive mesh approaches is compared identifying potential areas for improvement and providing mesh generation guidance for future workshops.

mesh adaptation high-lift 2D airfoil↗

NASA NTRSDate not supplied

Comparing Unstructured Adaptive Mesh Solutions for the High Lift Common Research Model Airfoil

mesh adaptation↗

DOE OSTI2024

Level-set topology optimization with PDE generated conformal meshes

This paper presents a level-set topology optimization approach that uses conformal meshes for the analysis of the displacement field. The structure’s boundary is represented by the iso-contour of a level-set field discretized on a fixed background design mesh. The conformal mesh is updated for each design iteration via a PDE based mesh morphing process that identifies the set of facets in the background mesh that are homeomorphic to the boundary and relaxes the homeomorphic mesh to conform to the structure’s boundary and ensure high element quality. The conformal mesh allows for a more accurate computation of the response versus density and some level-set based methods which interpolate material properties using the volume fraction. Numerical examples illustrate the proposed approach by optimizing linear-elastic two- and three-dimensional structures, wherein insight into the performance of the mesh morphing process is provided. The examples also highlight the scalability of the approach.

42 ENGINEERING↗

DOE OSTI2019

Target Formulation and Construction in Mesh Quality Improvement

In the Target-matrix Optimization Paradigm (TMOP), it’s long been understood that one must create a set of target matrices before the mesh can be optimized. But there is still no general method to create correct, effective targets in response to a specific mesh quality improvement goal. The TMOP literature describes how certain sets of target matrices can be used to control the shape or size of mesh elements, but those examples address only a fraction of the problems that can occur in mesh quality improvement and were not derived from a general framework for target matrix construction. In this work, a general method of target construction is introduced based on an independent set of geometric parameters which are intrinsic to the Jacobian matrices upon which TMOP is based. The parameters enable a systematic approach to target definition and construction. The approach entails two parts. The first part defines correspondences between available raw data (stuff about the mesh and/or the physical solution) and intermediate data (e.g., a field of error estimates). Once the correspondences are established, the raw data is processed into intermediate field data existing on mesh sample points. The second part is to create a model that represents the values of the geometric target parameters as functions of the intermediate data. The model is then tested numerically to establish model constants and effectiveness. This systematic approach to target construction is illustrated in a set of examples to show how it can be applied to common problems in mesh optimization such as equidistribution of geometric properties, preservation of existing good quality, and adaptation of the mesh to the solution. The result is a systematic method of target construction for TMOP which can be applied to a wide variety of planar and volume mesh quality improvement tasks.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

FY25 MOOSE Usability Improvements: 3D Meshing Capabilities, Initiation of Geometry Support for Monte Carlo Tools, and Enhancement of MOOSE/Workbench User Input Interactions

Usability improvements have been made to MOOSE and Workbench in FY25 to enhance usability and user workflows. Assorted enhancement have been made to MOOSE’s intrinsic meshing capabilities in order to enable more flexible and complex meshing of nuclear reactor systems, in particular for 3D applications. Mesh generators have been added to perform operations such as batch mesh generation, surface mesh generation, and creation of 3D transition layers. These mesh generation capabilities make it much easier to generate high quality non-extruded 3D meshes. Additionally, work to integrate Monte Carlo reactor physics simulations into MOOSE-based multi-physics workflows has reached another milestone with the implementation of the Constructive Solid Geometry (CSG) base framework. This framework lays the foundation for mesh generators to offer the user a generic CSG output option (as opposed to a finite element mesh). To support users, workshop on the MOOSE Reactor Module was delivered which featured hands-on examples using the NEAMS Workbench on INL’s High Performance Computing system. Recent updates to the NEAMS Workbench, WASP, and the MOOSE language server have introduced several improvements aimed at making MOOSE-based simulation setup and input management faster, more accurate, and easier to use. Key capabilities that have been added include multi-tab-stop autocompletion, visual input diagnostics, developer-directed data visualizations, upgraded ParaView integration, and Workspace-level file tracking. Together, these changes make it easier for users to build, validate, and manage complex MOOSE-based simulation models — especially those involving reusable components, included files, and datasets. The improvements are designed to save time, reduce input errors, and help users get to a successful simulation run faster, with more confidence in the results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1995

Parallel automated adaptive procedures for unstructured meshes

Consideration is given to the techniques required to support adaptive analysis of automatically generated unstructured meshes on distributed memory MIMD parallel computers. The key areas of new development are focused on the support of effective parallel computations when the structure of the numerical discretization, the mesh, is evolving, and in fact constructed, during the computation. All the procedures presented operate in parallel on already distributed mesh information. Starting from a mesh definition in terms of a topological hierarchy, techniques to support the distribution, redistribution and communication among the mesh entities over the processors is given, and algorithms to dynamically balance processor workload based on the migration of mesh entities are given. A procedure to automatically generate meshes in parallel, starting from CAD geometric models, is given. Parallel procedures to enrich the mesh through local mesh modifications are also given. Finally, the combination of these techniques to produce a parallel automated finite element analysis procedure for rotorcraft aerodynamics calculations is discussed and demonstrated.

Shephard, M. S.↗

NASA NTRS2004

The Influence of Mesh Density on the Impact Response of a Shuttle Leading-Edge Panel Finite Element Simulation

A study was performed to examine the influence of varying mesh density on an LS-DYNA simulation of a rectangular-shaped foam projectile impacting the space shuttle leading edge Panel 6. The shuttle leading-edge panels are fabricated of reinforced carbon-carbon (RCC) material. During the study, nine cases were executed with all possible combinations of coarse, baseline, and fine meshes of the foam and panel. For each simulation, the same material properties and impact conditions were specified and only the mesh density was varied. In the baseline model, the shell elements representing the RCC panel are approximately 0.2-in. on edge, whereas the foam elements are about 0.5-in. on edge. The element nominal edge-length for the baseline panel was halved to create a fine panel (0.1-in. edge length) mesh and doubled to create a coarse panel (0.4-in. edge length) mesh. In addition, the element nominal edge-length of the baseline foam projectile was halved (0.25-in. edge length) to create a fine foam mesh and doubled (1.0- in. edge length) to create a coarse foam mesh. The initial impact velocity of the foam was 775 ft/s. The simulations were executed in LS-DYNA version 960 for 6 ms of simulation time. Contour plots of resultant panel displacement and effective stress in the foam were compared at five discrete time intervals. Also, time-history responses of internal and kinetic energy of the panel, kinetic and hourglass energy of the foam, and resultant contact force were plotted to determine the influence of mesh density. As a final comparison, the model with a fine panel and fine foam mesh was executed with slightly different material properties for the RCC. For this model, the average degraded properties of the RCC were replaced with the maximum degraded properties. Similar comparisons of panel and foam responses were made for the average and maximum degraded models.

Jackson, Karen E.↗