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

An object-oriented programming of an explicit dynamics code: application to impact simulation

During the last fifty years, the development of better numerical methods and more powerful computers has been a major enterprise for the scientific community. Recent advances in computational softwares have lead to the possibility of solving more physical and complex problems (coupled problems, nonlinearities, high strain and high strain rate problems, etc.). The development of object-oriented programming leads to better structured codes for the finite element method and facilitates the development, the maintainability and the expandability of such codes. This paper presents an implementation in C++ of an explicit finite element program dedicated to the simulation of impacts. We first present a brief overview of the kinematics, the conservative and constitutive laws related to large deformation inelasticity. Then we present the design and the numerical implementation of some aspects developed with an emphasis on the object-oriented programming adopted. Finally, the efficiency and accuracy of the program are investigated through some benchmark tests

A design-for-casting integrated approach based on rapid simulation and modulus criterion

This paper presents a new approach to the design of cast components and their associated tools. The current methodology is analysed through a case study and its main disadvantages underlined. Then, in order to overcome these identified drawbacks, a new approach is proposed. Knowing that this approach is mainly based on a rapid simulation of the process, basics of a simplified physical model of solidification are presented as well as an associated modulus criterion. Finally, technical matters for a software prototype regarding the implementation of this Rapid Simulation Approach (RSA) in a CAD environment are detailed

Product Focused Freeform Fabrication Education

Presented in this paper is our experience of teaching freeform fabrication to students at the Missouri University of Science and Technology, and to high school students and teachers. The emphasis of the curriculum is exposing students to rapid product development technologies with the goal of creating awareness to emerging career opportunities in CAD/CAM. Starting from solid modeling, principles of freeform fabrication, to applications of rapid prototyping and manufacturing in industry sponsored product development projects, students can learn in-depth freeform fabrication technologies. Interactive course content with hands-on experience for product development is the key towards the success of the program.Mechanical Engineerin

Knowledge formalization in experience feedback processes : an ontology-based approach

Because of the current trend of integration and interoperability of industrial systems, their size and complexity continue to grow making it more difficult to analyze, to understand and to solve the problems that happen in their organizations. Continuous improvement methodologies are powerful tools in order to understand and to solve problems, to control the effects of changes and finally to capitalize knowledge about changes and improvements. These tools involve suitably represent knowledge relating to the concerned system. Consequently, knowledge management (KM) is an increasingly important source of competitive advantage for organizations. Particularly, the capitalization and sharing of knowledge resulting from experience feedback are elements which play an essential role in the continuous improvement of industrial activities. In this paper, the contribution deals with semantic interoperability and relates to the structuring and the formalization of an experience feedback (EF) process aiming at transforming information or understanding gained by experience into explicit knowledge. The reuse of such knowledge has proved to have significant impact on achieving themissions of companies. However, the means of describing the knowledge objects of an experience generally remain informal. Based on an experience feedback process model and conceptual graphs, this paper takes domain ontology as a framework for the clarification of explicit knowledge and know-how, the aim of which is to get lessons learned descriptions that are significant, correct and applicable

Large scale prop-fan structural design study. Volume 1: Initial concepts

In recent years, considerable attention has been directed toward improving aircraft fuel consumption. Studies have shown that the inherent efficiency advantage that turboprop propulsion systems have demonstrated at lower cruise speeds may now be extended to the higher speeds of today's turbofan and turbojet-powered aircraft. To achieve this goal, new propeller designs will require features such as thin, high speed airfoils and aerodynamic sweep, features currently found only in wing designs for high speed aircraft. This is Volume 1 of a 2 volume study to establish structural concepts for such advanced propeller blades, to define their structural properties, to identify any new design, analysis, or fabrication techniques which were required, and to determine the structural tradeoffs involved with several blade shapes selected primarily on the basis of aero/acoustic design considerations. The feasibility of fabricating and testing dynamically scaled models of these blades for aeroelastic testing was also established. The preliminary design of a blade suitable for flight use in a testbed advanced turboprop was conducted and is described in Volume 2

Working Notes from the 1992 AAAI Workshop on Automating Software Design. Theme: Domain Specific Software Design

The goal of this workshop is to identify different architectural approaches to building domain-specific software design systems and to explore issues unique to domain-specific (vs. general-purpose) software design. Some general issues that cut across the particular software design domain include: (1) knowledge representation, acquisition, and maintenance; (2) specialized software design techniques; and (3) user interaction and user interface

Heat flux evaluation in high temperature ring-on-ring contacts

A comprehensive methodology to investigate heat flux in a ring-on-ring tribometer is presented. Thermal fluxes under high contact pressures and temperature differences were evaluated through an experimental campaign and by a numerical procedure of inverse analysis applied to surface temperature measurements. An approximation of a two-dimensional time-dependent analytical solution for the temperature distribution was first developed and subsequently adapted to mimic the specific testing configuration characteristics; the problem was finally simplified to enable further inverse analysis. Experiments were performed using an innovative high temperature ring-on-ring tribometer. The evaluated contact heat transfer rates were reported as a function of normal load and temperature difference between the discs under steady-state conditions; the results reported here show that, in the present test configuration, the temperature difference has stronger influence than the applied load in terms of heat transfer induced by contact