Lead extrusion analysis by finite volume method

Computational numerical simulation is nowadays largely applied in the design and analysis of metal forming process. Extrusion of metals is one main forming process largely applied in the manufacturing of metallic products or parts. Historically, the Finite Element Method has been applied for decades in metal extrusion analysis [4]. However, recently in the academy, there is a trend to use Finite Volume Method: literature suggests that metal flow by extrusion can be analyzed by the flow formulation [1, 2]. Thus, metal flow can be modelled such us an incompressible viscous fluid [2]. This hypothesis can be assumed because extrusion process is an isochoric process. The MacCormack Method is commonly used to simulate compressible fluid flow by the finite volume method [3]. However, metal extrusion and incompressible fluid flow do not present state equations for the evolution of pressure, and therefore, a velocity-pressure coupling method is necessary to obtain a consistent velocity and pressure fields [3]. Present work proposes a new numerical scheme to obtain information about metal flow in the extrusion process, in steady state. The governing equations were discretized by Finite Volume Method, using the Explicit MacCormack Method to structured and collocated mesh. The SIMPLE Method was applied to attain pressure-velocity coupling [3]. These new numerical scheme was applied to forward extrusion process of lead. The incompressible metal extrusion velocity fields achieved faster convergence and a good agreement with analytical and experimental results obtained from literature. The MacCormack Method applied for metals produced consistent results without the need of artificial viscosity as employed by the compressible flow simulation approaches. Furthermore, the present numerical results also suggest that MacCormack Method and SIMPLE can be applied in the solution of metal forming processes besides the traditional application for compressible fluid flow

3D discrete element modeling of concrete: study of the rolling resistance effects on the macroscopic constitutive behavior

The Discrete Element Method (DEM) is appropriate for modeling granular materials [14] but also cohesive materials as concrete when submitted to a severe loading such an impact leading to fractures or fragmentation in the continuum [1, 5, 6, 8]. Contrarily to granular materials, the macroscopic constitutive behavior of a cohesive material is not directly linked to contact interactions between the rigid Discrete Elements (DE) and interaction laws are then defined between DE surrounding each DE. Spherical DE are used because the contact detection is easy to implement and the computation time is reduced in comparison with the use of 3D DE with a more complex shape. The element size is variable and the assembly is disordered to prevent preferential cleavage planes. The purpose of this paper is to highlight the influence of DE rotations on the macroscopic non-linear quasi-static behavior of concrete. Classically, the interactions between DE are modeled by spring-like interactions based on displacements and rotation velocities of DE are only controlled by tangential forces perpendicular to the line linking the two sphere centroids. The disadvantage of this modeling with only spring-like interactions based on displacements is that excessive rolling occurs under shear, therefore the macroscopic behavior of concrete is too brittle. To overcome this problem a non linear Moment Transfer Law (MTL) is introduced to add a rolling resistance to elements. This solution has no influence on the calculation cost and allows a more accurate macroscopic representation of concrete behavior. The identification process of material parameters is given and simulations of tests performed on concrete samples are shown

Continuum modelling and simulation of granular flows through their many phases

We propose and numerically implement a constitutive framework for granular media that allows the material to traverse through its many common phases during the flow process. When dense, the material is treated as a pressure sensitive elasto-viscoplastic solid obeying a yield criterion and a plastic flow rule given by the $\mu(I)$ inertial rheology of granular materials. When the free volume exceeds a critical level, the material is deemed to separate and is treated as disconnected, stress-free media. A Material Point Method (MPM) procedure is written for the simulation of this model and many demonstrations are provided in different geometries. By using the MPM framework, extremely large strains and nonlinear deformations, which are common in granular flows, are representable. The method is verified numerically and its physical predictions are validated against known results

Discrete element modelling of rock cutting processes interaction with evaluation of tool wear

The document presents a numerical model of rocks and soils using spherical Discrete Elements, also called Distinct Elements. The motion of spherical elements is described by means of equations of rigid body dynamics. Explicit integration in time yields high computational efficiency. Spherical elements interact among one another with contact forces, both in normal and tangential directions. Efficient contact search scheme based on the octree structures has been implemented. Special constitutive model of contact interface taking into account cohesion forces allows us to model fracture and decohesion of materials. Numerical simulation predicts wear of rock cutting tools. The developed numerical algorithm of wear evaluation allows us us to predict evolution of the shape of the tool caused by wear. Results of numerical simulation are validated by comparison with experimental data.Postprint (published version

CBS stabilization in dynamics of solids using explicit time integration

The characteristic based split (CBS) stabilization procedure developed originally in fluid mechanics has been adapted successfully to solid mechanics problems. The CBS algorithm has been implemented within a finite element program using an explicit time integration scheme. Volumetric locking of linear triangular and tetrahedral elements has been successfully eliminated. The performance of the numerical algorithm is illustrated with numerical results. Comparisons with an alternative stabilization technique based on the Finite Calculus method also are given.Postprint (published version