A scalable parallel finite element framework for growing geometries. Application to metal additive manufacturing

This work introduces an innovative parallel, fully-distributed finite element framework for growing geometries and its application to metal additive manufacturing. It is well-known that virtual part design and qualification in additive manufacturing requires highly-accurate multiscale and multiphysics analyses. Only high performance computing tools are able to handle such complexity in time frames compatible with time-to-market. However, efficiency, without loss of accuracy, has rarely held the centre stage in the numerical community. Here, in contrast, the framework is designed to adequately exploit the resources of high-end distributed-memory machines. It is grounded on three building blocks: (1) Hierarchical adaptive mesh refinement with octree-based meshes; (2) a parallel strategy to model the growth of the geometry; (3) state-of-the-art parallel iterative linear solvers. Computational experiments consider the heat transfer analysis at the part scale of the printing process by powder-bed technologies. After verification against a 3D benchmark, a strong-scaling analysis assesses performance and identifies major sources of parallel overhead. A third numerical example examines the efficiency and robustness of (2) in a curved 3D shape. Unprecedented parallelism and scalability were achieved in this work. Hence, this framework contributes to take on higher complexity and/or accuracy, not only of part-scale simulations of metal or polymer additive manufacturing, but also in welding, sedimentation, atherosclerosis, or any other physical problem where the physical domain of interest grows in time

Process planning for thick-film mask projection micro stereolithography

Mask Projection micro Stereolithography (MPuSLA) is an additive manufacturing process used to build physical components out of a photopolymer resin. Existing MPuSLA technology cut the CAD model of part into slices by horizontal planes and the slices are stored as bitmaps. A layer corresponding to the shape of each bitmap gets cured. This layer is coated with a fresh layer of resin by lowering the Z-stage inside a vat holding the resin and the next layer is cured on top of it. In our Thick-film MPuSLA(TfMPuSLA) system, incident radiation, patterned by a dynamic mask, passes through a fixed transparent substrate to cure photopolymer resin. The existing MPuSLA fabrication models can work only for controlling the lateral dimension, without any control over the thickness of the cured part. The proposed process plan controls both the lateral dimensions and the thickness of profile of the cured part. In this thesis, a novel process planning for TfMPuSLA method is developed, to fabricate films on fixed flat substrate. The process of curing a part using this system is analytically modeled as the column cure model. It is different from the conventional process - layer cure model. Column means that a CAD model of part is discretized into vertical columns instead of being sliced into horizontal layers, and all columns get cured simultaneously till the desired heights. The process planning system is modularized into geometrical, chemical, optical, mathematical and physical modules and validated by curing test parts on our system. The thesis formulates a feasible process planning method, providing a strong basis for continued investigation of MPuSLA technology in microfabrication, such as micro lens fabrication.M.S.Committee Chair: Rosen, David W.; Committee Member: Das, Suman; Committee Member: Grover, Martha A

Large-scale tree-based unfitted finite elements for metal additive manufacturing

This thesis addresses large-scale numerical simulations of partial differential equations posed on evolving geometries. Our target application is the simulation of metal additive manufacturing (or 3D printing) with powder-bed fusion methods, such as Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS) or Electron-Beam Melting (EBM). The simulation of metal additive manufacturing processes is a remarkable computational challenge, because processes are characterised by multiple scales in space and time and multiple complex physics that occur in intricate three-dimensional growing-in-time geometries. Only the synergy of advanced numerical algorithms and high-performance scientific computing tools can fully resolve, in the short run, the simulation needs in the area. The main goal of this Thesis is to design a a novel highly-scalable numerical framework with multi-resolution capability in arbitrarily complex evolving geometries. To this end, the framework is built by combining three computational tools: (1) parallel mesh generation and adaptation with forest-of-trees meshes, (2) robust unfitted finite element methods and (3) parallel finite element modelling of the geometry evolution in time. Our numerical research is driven by several limitations and open questions in the state-of-the-art of the three aforementioned areas, which are vital to achieve our main objective. All our developments are deployed with high-end distributed-memory implementations in the large-scale open-source software project FEMPAR. In considering our target application, (4) temporal and spatial model reduction strategies for thermal finite element models are investigated. They are coupled to our new large-scale computational framework to simplify optimisation of the manufacturing process. The contributions of this Thesis span the four ingredients above. Current understanding of (1) is substantially improved with rigorous proofs of the computational benefits of the 2:1 k-balance (ease of parallel implementation and high-scalability) and the minimum requirements a parallel tree-based mesh must fulfil to yield correct parallel finite element solvers atop them. Concerning (2), a robust, optimal and scalable formulation of the aggregated unfitted finite element method is proposed on parallel tree-based meshes for elliptic problems with unfitted external contour or unfitted interfaces. To the author’s best knowledge, this marks the first time techniques (1) and (2) are brought together. After enhancing (1)+(2) with a novel parallel approach for (3), the resulting framework is able to mitigate a major performance bottleneck in large-scale simulations of metal additive manufacturing processes by powder-bed fusion: scalable adaptive (re)meshing in arbitrarily complex geometries that grow in time. Along the development of this Thesis, our application problem (4) is investigated in two joint collaborations with the Monash Centre for Additive Manufacturing and Monash University in Melbourne, Australia. The first contribution is an experimentally-supported thorough numerical assessment of time-lumping methods, the second one is a novel experimentally-validated formulation of a new physics-based thermal contact model, accounting for thermal inertia and suitable for model localisation, the so-called virtual domain approximation. By efficiently exploiting high-performance computing resources, our new computational framework enables large-scale finite element analysis of metal additive manufacturing processes, with increased fidelity of predictions and dramatical reductions of computing times. It can also be combined with the proposed model reductions for fast thermal optimisation of the manufacturing process. These tools open the path to accelerate the understanding of the process-to-performance link and digital product design and certification in metal additive manufacturing, two milestones that are vital to exploit the technology for mass-production.Aquesta tesi tracta la simulació a gran escala d'equacions en derivades parcials sobre geometries variables. L'aplicació principal és la simulació de procesos de fabricació additiva (o impressió 3D) amb metalls i per mètodes de fusió de llit de pols, com ara Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS) o Electron-Beam Melting (EBM). La simulació d'aquests processos és un repte computacional excepcional, perquè els processos estan caracteritzats per múltiples escales espaitemporals i múltiples físiques que tenen lloc sobre geometries tridimensionals complicades que creixen en el temps. La sinèrgia entre algorismes numèrics avançats i eines de computació científica d'alt rendiment és la única via per resoldre completament i a curt termini les necessitats en simulació d'aquesta àrea. El principal objectiu d'aquesta tesi és dissenyar un nou marc numèric escalable de simulació amb capacitat de multiresolució en geometries complexes i variables. El nou marc es construeix unint tres eines computacionals: (1) mallat paral·lel i adaptatiu amb malles de boscs d'arbre, (2) mètodes d'elements finits immersos robustos i (3) modelització en paral·lel amb elements finits de geometries que creixen en el temps. Algunes limitacions i problemes oberts en l'estat de l'art, que són claus per aconseguir el nostre objectiu, guien la nostra recerca. Tots els desenvolupaments s'implementen en arquitectures de memòria distribuïda amb el programari d'accés obert FEMPAR. Quant al problema d'aplicació, (4) s'investiguen models reduïts en espai i temps per models tèrmics del procés. Aquests models reduïts s'acoplen al nostre marc computacional per simplificar l'optimització del procés. Les contribucions d'aquesta tesi abasten els quatre punts de dalt. L'estat de l'art de (1) es millora substancialment amb proves riguroses dels beneficis computacionals del 2:1 balancejat (fàcil paral·lelització i alta escalabilitat), així com dels requisits mínims que aquest tipus de mallat han de complir per garantir que els espais d'elements finits que s'hi defineixin estiguin ben posats. Quant a (2), s'ha formulat un mètode robust, òptim i escalable per agregació per problemes el·líptics amb contorn o interface immerses. Després d'augmentar (1)+(2) amb un nova estratègia paral·lela per (3), el marc de simulació resultant mitiga de manera efectiva el principal coll d'ampolla en la simulació de processos de fabricació additiva en llits de pols de metall: adaptivitat i remallat escalable en geometries complexes que creixen en el temps. Durant el desenvolupament de la tesi, es col·labora amb el Monash Centre for Additive Manufacturing i la Universitat de Monash de Melbourne, Austràlia, per investigar el problema d'aplicació. En primer lloc, es fa una anàlisi experimental i numèrica exhaustiva dels mètodes d'aggregació temporal. En segon lloc, es proposa i valida experimental una nova formulació de contacte tèrmic que té en compte la inèrcia tèrmica i és adequat per a localitzar el model, l'anomenada aproximació per dominis virtuals. Mitjançant l'ús eficient de recursos computacionals d'alt rendiment, el nostre nou marc computacional fa possible l'anàlisi d'elements finits a gran escala dels processos de fabricació additiva amb metalls, amb augment de la fidelitat de les prediccions i reduccions significatives de temps de computació. Així mateix, es pot combinar amb els models reduïts que es proposen per l'optimització tèrmica del procés de fabricació. Aquestes eines contribueixen a accelerar la comprensió del lligam procés-rendiment i la digitalització del disseny i certificació de productes en fabricació additiva per metalls, dues fites crucials per explotar la tecnologia en producció en massa.Postprint (published version

Modeling EMI Resulting from a Signal Via Transition Through Power/Ground Layers

Signal transitioning through layers on vias are very common in multi-layer printed circuit board (PCB) design. For a signal via transitioning through the internal power and ground planes, the return current must switch from one reference plane to another reference plane. The discontinuity of the return current at the via excites the power and ground planes, and results in noise on the power bus that can lead to signal integrity, as well as EMI problems. Numerical methods, such as the finite-difference time-domain (FDTD), Moment of Methods (MoM), and partial element equivalent circuit (PEEC) method, were employed herein to study this problem. The modeled results are supported by measurements. In addition, a common EMI mitigation approach of adding a decoupling capacitor was investigated with the FDTD method

[Activity of Institute for Computer Applications in Science and Engineering]

This report summarizes research conducted at the Institute for Computer Applications in Science and Engineering in applied mathematics, fluid mechanics, and computer science

A Novel Propeller Design for Micro-Swimming robot

The applications of a micro-swimming robot such as minimally invasive surgery, liquid pipeline robot etc. are widespread in recent years. The potential application fields are so inspiring, and it is becoming more and more achievable with the development of microbiology and Micro-Electro-Mechanical Systems (MEMS). The aim of this study is to improve the performance of micro-swimming robot through redesign the structure. To achieve the aim, this study reviewed all of the modelling methods of low Reynolds number flow including Resistive-force Theory (RFT), Slender Body Theory (SBT), and Immersed Boundary Method (IBM) etc. The swimming model with these methods has been analysed. Various aspects e.g. hydrodynamic interaction, design, development, optimisation and numerical methods from the previous researches have been studied. Based on the previous design of helix propeller for micro-swimmer, this study has proposed a novel propeller design for a micro-swimming robot which can improve the velocity with simplified propulsion structure. This design has adapted the coaxial symmetric double helix to improve the performance of propulsion and to increase stability. The central lines of two helical tails overlap completely to form a double helix structure, and its tail radial force is balanced with the same direction and can produce a stable axial motion. The verification of this design is conducted using two case studies. The first one is a pipe inspection robot which is in mm scale and swims in high viscosity flow that satisfies the low Reynolds number flow condition. Both simulation and experiment analysis are conducted for this case study. A cross-development method is adopted for the simulation analysis and prototype development. The experiment conditions are set up based on the simulation conditions. The conclusion from the analysis of simulation results gives suggestions to improve design and fabrication for the prototype. Some five revisions of simulation and four revisions of the prototype have been completed. The second case study is the human blood vessel robot. For the limitations of fabrication technology, only simulation is conducted, and the result is compared with previous researches. The results show that the proposed propeller design can improve velocity performance significantly. The main outcomes of this study are the design of a micro-swimming robot with higher velocity performance and the validation from both simulation and experiment

SCEE 2008 book of abstracts : the 7th International Conference on Scientific Computing in Electrical Engineering (SCEE 2008), September 28 – October 3, 2008, Helsinki University of Technology, Espoo, Finland

This report contains abstracts of presentations given at the SCEE 2008 conference.reviewe

Development of a Real-time Ultra-wideband See Through Wall Imaging Radar System

Ultra-Wideband (UWB) See-Through-Wall (STW) technology has emerged as a musthave enabling technology by both the military and commercial sectors. As a pioneer in this area, we have led the research in addressing many of the fundamental STW questions. This dissertation is to investigate and resolve a few hurdles in advancing this technology, and produce a realizable high performance STW platform system, which will aid the STW community to find the ultimate answer through experimental and theoretical work. The architectures of a realizable STW imaging system are thoroughly examined and studied. We present both a conceptual system based on RF instruments and a standalone real-time system based on custom design, which utilize reconfigurable design architecture and allows scaling down/up to a desired UWB operating frequency with little difficulty. The systems will serve as a high performance platform for STW study and other related UWB applications. Along the way to a complete STW system, we have developed a simplified transmission line model for wall characteristic prediction; we have developed a scalable synthetic aperture array including both the RF part and the switch control/synchronization part; we have proposed a cost-effective and efficient UWB data acquisition method for real-time STW application based on equivalent-time sampling method. The measurement results reported here include static image formation and tracking moveable targets behind the wall. Even though digital signal processing to generate radar images is not the focus of this research, simple methods for image formation have been implemented and results are very encouraging