Design of meso-scale cellular structure for rapid manufacturing

Customized cellular material is a relatively new area made possible by advancements in rapid manufacturing technologies. Rapid manufacturing is ideal for the production of customized cellular structure, especially on the meso scale, due to the size and complexity of the design. The means to produce this type of structure now exist, but the processes to design the structure are not well developed. The manual design of customized cellular material is not realistic due to the large number of features. Currently there are few tools available that aid in the design of this type of material. In this thesis, an automated tool to design customized cellular structure is presented.M.S.Committee Chair: Rosen, David; Committee Member: Choi, Seung-Kyum; Committee Member: Sitaraman, Sures

Simulation of pore-scale flow using finite element-methods

I present a new finite element (FE) simulation method to simulate pore-scale flow. Within the pore-space, I solve a simplified form of the incompressible Navier-Stoke’s equation, yielding the velocity field in a two-step solution approach. First, Poisson’s equation is solved with homogeneous boundary conditions, and then the pore pressure is computed and the velocity field obtained for no slip conditions at the grain boundaries. From the computed velocity field I estimate the effective permeability of porous media samples characterized by thin section micrographs, micro-CT scans and synthetically generated grain packings. This two-step process is much simpler than solving the full Navier Stokes equation and therefore provides the opportunity to study pore geometries with hundreds of thousands of pores in a computationally more cost effective manner than solving the full Navier-Stoke’s equation. My numerical model is verified with an analytical solution and validated on samples whose permeabilities and porosities had been measured in laboratory experiments (Akanji and Matthai, 2010). Comparisons were also made with Stokes solver, published experimental, approximate and exact permeability data. Starting with a numerically constructed synthetic grain packings, I also investigated the extent to which the details of pore micro-structure affect the hydraulic permeability (Garcia et al., 2009). I then estimate the hydraulic anisotropy of unconsolidated granular packings. With the future aim to simulate multiphase flow within the pore-space, I also compute the radii and derive capillary pressure from the Young-Laplace equation (Akanji and Matthai,2010