Thermo-mechanical modeling for selective laser melting

Selective Laser Melting (SLM) is an Additive Manufacturing (AM) process where a powder bed is locally melted with a laser. Layer by layer, complex three dimensional geometries including overhangs can be produced. Up to date, the material and process development of SLM mainly relies on experimental studies that are time intensive and costly. Simulation tools offer the potential to gain a deeper understanding of the process - structure - property interaction. This can help to find optimal process parameters for individualized components and the processing of innovative powder materials. In this work, a rigorous thermo-mechanical framework for the finite deformation phase change problem is formulated. Beside the phase change, an additional peculiarity of the SLM process is the fusion of powder particles. Regarding the numerical solution, meshfree methods seem to be especially suited because the treatment of particle fusion is intrinsic to the formulation. The complex moving boundaries between liquid melt and solid metal can be resolved without additional numerical effort. The recently introduced Optimal Transportation Meshfree Method (OTM) has been chosen since it was promoted as a versatile tool for both fluid and solid mechanics. Special focus lays on the modeling of laser-matter interaction. The laser beam can be divided into moving discrete energy portions (rays) that are traced in space and time. In order to compute the reflection and absorption, usually a triangulation of the free surface is conducted. Within meshfree methods, this is a very expensive operation. To avoid the need for surface triangulation, a computationally efficient algorithm is presented which can easily be combined with meshfree methods. Both melt pool dynamics and residual stress formation are studied with the developed numerical framework. The influence of laser heating and cooling conditions on melting and consolidation is investigated. Although the numerical results are promising, it was found that the OTM exhibits some limitations. Therefore, the accuracy of the method is critically discussed

Highly accurate operator factorization methods for the integral fractional Laplacian and its generalization

In this paper, we propose a new class of operator factorization methods to discretize the integral fractional Laplacian $(-\Delta)^\frac{\alpha}{2}$ for $\alpha \in (0, 2)$. The main advantage of our method is to easily increase numerical accuracy by using high-degree Lagrange basis functions, but remain the scheme structure and computer implementation unchanged. Moreover, our discretization of the fractional Laplacian results in a symmetric (multilevel) Toeplitz differentiation matrix, which not only saves memory cost in simulations but enables efficient computations via the fast Fourier transforms. The performance of our method in both approximating the fractional Laplacian and solving the fractional Poisson problems was detailedly examined. It shows that our method has an optimal accuracy of ${\mathcal O}(h^2)$ for constant or linear basis functions, while ${\mathcal O}(h^4)$ if quadratic basis functions are used, with $h$ a small mesh size. Note that this accuracy holds for any $\alpha \in (0, 2)$ and can be further increased if higher-degree basis functions are used. If the solution of fractional Poisson problem satisfies $u \in C^{m, l}(\bar{\Omega})$ for $m \in {\mathbb N}$ and $0 < l < 1$, then our method has an accuracy of ${\mathcal O}\big(h^{\min\{m+l,\, 2\}}\big)$ for constant and linear basis functions, while ${\mathcal O}\big(h^{\min\{m+l,\, 4\}}\big)$ for quadratic basis functions. Additionally, our method can be readily applied to study generalized fractional Laplacians with a symmetric kernel function, and numerical study on the tempered fractional Poisson problem demonstrates its efficiency.Comment: 21 pages, 7 figure

Geometric Numerical Integration

The subject of this workshop was numerical methods that preserve geometric properties of the flow of an ordinary or partial differential equation. This was complemented by the question as to how structure preservation affects the long-time behaviour of numerical methods

Discrete-continuum hybrid modelling of flowing and static regimes

Bulk handling, transport and processing of granular materials and powders are fundamental operations in a wide range of industrial processes and geophysical phenomena. Particulate materials, which can be found in nature, are usually characterized by grain size which can range across several scales: from nanometre to the order of metre. Depending on the volume fraction and shear strain conditions, granular materials can have different behaviours and often can be expressed as a new state of matter with properties of solids, liquids and gases. For the above reasons both the experimental and the numerical analysis of granular media is still a difficult task and the prediction of their dynamic behaviour still represents nowadays an important challenge. The main goal of the current thesis is the development of a numerical strategy with the objective of studying the macroscopic behaviour of dry granular flows in quasi-static and dense flow regime. The problem is defined in a continuum mechanics framework and the balance laws, which govern the behaviour of a solid body, are solved by using a Lagrangian formalism. The Material Point Method (MPM), a particle-based method, is chosen due to its features which make it very suitable for the solution of large deformation problems involving complex history-dependent constitutive laws. An irreducible formulation using a Mohr-Coulomb constitutive law, which takes into account geometric non-linearities, is implemented within the MPM framework. The numerical strategy is verified and validated against several benchmark tests and experimental results, available in the literature. Further, a mixed formulation is implemented for the solution of granular flows that undergo undrained conditions. Finally, the developed MPM strategy is used and tested against the experimental study performed for the characterization of the flowability of several types of sucrose. The capabilities and limitations of this numerical strategy are observed and discussed and the bases for future research are outlined.El manejo, el transporte y el procesamiento de materiales granulares y polvo son operaciones fundamentales en una amplia gama de procesos industriales y de fenómenos geofísicos. Los materiales particulados, que pueden ser encontrados en la naturaleza, generalmente están caracterizados por el tamaño del grano, que puede variar entre varios órdenes de magnitud: desde el nanómetro hasta el orden de los metros. En función de las condiciones de fracción volumétrica y de deformación de cortante, los materiales granulares pueden tener un comportamiento diferente y a menudo pueden expresarse como un nuevo estado de materia con propiedades de sólidos, de líquidos y de gases. A causa de las observaciones antes mencionadas, tanto el análisis experimental como la simulación numérica de medios granulares es aún una tarea compleja y la predicción de su comportamiento dinámico representa aun hoy día un desafío muy importante. El principal objetivo de esta tesis es el desarrollo de una estrategia numérica con la finalidad de estudiar el comportamiento macroscópico de los flujos de medios granulares secos en régimen cuasiestático y en régimen dinámico. El problema está definido en el contexto de la mecánica de medios continuos y las leyes de equilibrio, que gobiernan el comportamiento del cuerpo sólido, y están resueltas mediante un formalismo Lagrangiano. El Metodo de los Puntos Materiales (MPM), método basado en el concepto de discretización del cuerpo sólido en partículas, está elegido por sus características que lo convierten en una técnica apropiada para resolver problemas de grandes deformaciones donde se tienen que utilizar complejas leyes constitutivas. En el marco del MPM está implementada una formulación irreducible que usa una ley constitutiva de Mohr-Coulomb y que tiene en cuenta no-linealidades geométricas. La estrategia numérica está verificada y validada con respecto a tests de referencia y resultados experimentales disponibles en la literatura. Además, se ha implementado una formulación mixta para resolver casos de flujo granular en condiciones no drenadas. Por último, la estrategia MPM desarrollada está utilizada y evaluada con respecto a un estudio experimental realizado para la caracterización de la fluidez de diferentes tipologías de azúcar. También se presentan unas observaciones y discusión sobre las capacidades y las limitaciones de esta herramienta numérica y se describen las bases de una investigación futura.Postprint (published version

Discrete-continuum hybrid modelling of flowing and static regimes

Bulk handling, transport and processing of granular materials and powders are fundamental operations in a wide range of industrial processes and geophysical phenomena. Particulate materials, which can be found in nature, are usually characterized by grain size which can range across several scales: from nanometre to the order of metre. Depending on the volume fraction and shear strain conditions, granular materials can have different behaviours and often can be expressed as a new state of matter with properties of solids, liquids and gases. For the above reasons both the experimental and the numerical analysis of granular media is still a difficult task and the prediction of their dynamic behaviour still represents nowadays an important challenge. The main goal of the current thesis is the development of a numerical strategy with the objective of studying the macroscopic behaviour of dry granular flows in quasi-static and dense flow regime. The problem is defined in a continuum mechanics framework and the balance laws, which govern the behaviour of a solid body, are solved by using a Lagrangian formalism. The Material Point Method (MPM), a particle-based method, is chosen due to its features which make it very suitable for the solution of large deformation problems involving complex history-dependent constitutive laws. An irreducible formulation using a Mohr-Coulomb constitutive law, which takes into account geometric non-linearities, is implemented within the MPM framework. The numerical strategy is verified and validated against several benchmark tests and experimental results, available in the literature. Further, a mixed formulation is implemented for the solution of granular flows that undergo undrained conditions. Finally, the developed MPM strategy is used and tested against the experimental study performed for the characterization of the flowability of several types of sucrose. The capabilities and limitations of this numerical strategy are observed and discussed and the bases for future research are outlined.El manejo, el transporte y el procesamiento de materiales granulares y polvo son operaciones fundamentales en una amplia gama de procesos industriales y de fenómenos geofísicos. Los materiales particulados, que pueden ser encontrados en la naturaleza, generalmente están caracterizados por el tamaño del grano, que puede variar entre varios órdenes de magnitud: desde el nanómetro hasta el orden de los metros. En función de las condiciones de fracción volumétrica y de deformación de cortante, los materiales granulares pueden tener un comportamiento diferente y a menudo pueden expresarse como un nuevo estado de materia con propiedades de sólidos, de líquidos y de gases. A causa de las observaciones antes mencionadas, tanto el análisis experimental como la simulación numérica de medios granulares es aún una tarea compleja y la predicción de su comportamiento dinámico representa aun hoy día un desafío muy importante. El principal objetivo de esta tesis es el desarrollo de una estrategia numérica con la finalidad de estudiar el comportamiento macroscópico de los flujos de medios granulares secos en régimen cuasiestático y en régimen dinámico. El problema está definido en el contexto de la mecánica de medios continuos y las leyes de equilibrio, que gobiernan el comportamiento del cuerpo sólido, y están resueltas mediante un formalismo Lagrangiano. El Metodo de los Puntos Materiales (MPM), método basado en el concepto de discretización del cuerpo sólido en partículas, está elegido por sus características que lo convierten en una técnica apropiada para resolver problemas de grandes deformaciones donde se tienen que utilizar complejas leyes constitutivas. En el marco del MPM está implementada una formulación irreducible que usa una ley constitutiva de Mohr-Coulomb y que tiene en cuenta no-linealidades geométricas. La estrategia numérica está verificada y validada con respecto a tests de referencia y resultados experimentales disponibles en la literatura. Además, se ha implementado una formulación mixta para resolver casos de flujo granular en condiciones no drenadas. Por último, la estrategia MPM desarrollada está utilizada y evaluada con respecto a un estudio experimental realizado para la caracterización de la fluidez de diferentes tipologías de azúcar. También se presentan unas observaciones y discusión sobre las capacidades y las limitaciones de esta herramienta numérica y se describen las bases de una investigación futura

A sharp interface isogeometric strategy for moving boundary problems

The proposed methodology is first utilized to model stationary and propagating cracks. The crack face is enriched with the Heaviside function which captures the displacement discontinuity. Meanwhile, the crack tips are enriched with asymptotic displacement functions to reproduce the tip singularity. The enriching degrees of freedom associated with the crack tips are chosen as stress intensity factors (SIFs) such that these quantities can be directly extracted from the solution without a-posteriori integral calculation. As a second application, the Stefan problem is modeled with a hybrid function/derivative enriched interface. Since the interface geometry is explicitly defined, normals and curvatures can be analytically obtained at any point on the interface, allowing for complex boundary conditions dependent on curvature or normal to be naturally imposed. Thus, the enriched approximation naturally captures the interfacial discontinuity in temperature gradient and enables the imposition of Gibbs-Thomson condition during solidification simulation. The shape optimization through configuration of finite-sized heterogeneities is lastly studied. The optimization relies on the recently derived configurational derivative that describes the sensitivity of an arbitrary objective with respect to arbitrary design modifications of a heterogeneity inserted into a domain. The THB-splines, which serve as the underlying approximation, produce sufficiently smooth solution near the boundaries of the heterogeneity for accurate calculation of the configurational derivatives. (Abstract shortened by ProQuest.