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Cross
Cross
u
t
NAFENS World Congress
vancouver Nay 2007
z
Solid regions appear in blue
End
View
Top view
Solidification Strand
3
NAFENS World Congress
vancouver Nay 2007
Argon bubble injection:
closely coupled L-E approach
L particles
Incorp in cont
CFD code
Embed with
mass flux
effects
Eval
integrated
path
NAFENS World Congress
vancouver Nay 2007
Clustering of argon bubbles
1
NAFENS World Congress
vancouver Nay 2007
Computations were also performed to estimate the effects of
EMB on the free surface . For this the Maxwell equations were
solved, which with the usual MHD assumptions, lead to:
Continuity of magnetic flux:
Ohm's Law for conducting metals
Magnetic Transport, or Induction equation
Lorentz force:
Note: Terms containing the velocity U, are only important when Rm
(=LU/h)> 1
0 = B .
- = E where ), B U + E ( = J
m
2
1
= where, B + ) B U ( =
t
1
NAFENS World Congress
vancouver Nay 2007
B=0T
B=0.4T
Flow suppressed
here
Fluid behaviour under EMB conditions
NAFENS World Congress
vancouver Nay 2007
Coupled EM-flow calculations
For most practical calculations in metals
processing:
The EM field influences the flow and
thermal fields
BUT the thermo-fluid phenomena has little
influence of the EM fields
Hence, essentially one way coupling
So calculate the EM field and calculate the
thermal and flow loads in the CFD
calculation
Can implement above model in any good
CFD code!
2
NAFENS World Congress
vancouver Nay 2007
Welding processes simulation - natural
multi-physics
Processes involve:
free surface flow
electromagnetic forces
heat transfer with solidification/melting
development of non-linear stress
Ideal candidate for multi-physics modelling
NAFENS World Congress
vancouver Nay 2007
T-Junction arc weld simulation
1
NAFENS World Congress
vancouver Nay 2007
Experiment and simulation
T-junction section,
highlighting HAZ region
X
Y
Z
Model: T_J
CASE1: PHYSICA Results
Step: 1 TIME: 0
Nodal LFN
Max = 1 Min = 0
.909E-1
.182
.273
.364
.455
.545
.636
.727
.818
.909
FEMGV 5.1-01 28 FEB 2000 Greenwich University
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GREENWICH
NAFENS World Congress
vancouver Nay 2007
Distortion of T-junction due to heat source
Heat source
2
NAFENS World Congress
vancouver Nay 2007
Weld pool dynamics
Velocity vectors in crossection
Lorentz force distribution in the
weld-pool
NAFENS World Congress
vancouver Nay 2007
Distortion of T-junction due to heat source
Distortion
3
NAFENS World Congress
vancouver Nay 2007
Welding multi-physics BUT . .
Welding involves:
free surface fluid flow
heat transfer and solidification/melting
electro-magnetic fields
non-linear stress
BUT . . no coupling back:
from thermo-fluids to EM field
from stress calculation to thermo-fluids
SO . . reasonably loosely coupled
NAFENS World Congress
vancouver Nay 2007
Generic Dynamic Fluid Structure Interaction
Closely coupled multi-disciplinary problem
Time & space accurate
Very challenging in every respect.
Issue of GCL
Implementation of boundary conditions.
Features of single software framework:
Consistency of mesh.
Single database & memory map.
Compatibility in the solution approaches FV-UM.
Traction
boundary
condition
CFD
CSM
Deformation
Mesh
adaptation
1
NAFENS World Congress
vancouver Nay 2007
Three Phase Approach
CMD
1 +
n n
t t
m m m
F d K =
CSD
( ) t
s
F Kd d C d M = + +
fs m
on u
fs fs p
= on t
fs
on d
Generalised
Newtonian
Continuity
CFD
NAFENS World Congress
vancouver Nay 2007
Vertex Based
Mesh
Element
Gauss
Point
Finite Volume
Cell Centred
Control
Volume
Control
Volume
Integration
Point
x
Finite Element
x
Node
Finite Volume
x
x
x
x
x
x
x
x x
x
x
PHYSICA
Spatial Discretisation for closely coupled
multi-physics
Unstructured mesh
CFD
Cell centred
Or mixed CC- VB
FV
CSM
Vertex based
FV/FE
2
NAFENS World Congress
vancouver Nay 2007
Dynamic fluid-structure interaction
Targeted at
problems involving
flow induced
vibrations
Use dynamic
structural
equations and
Navier-Stokes flow
equations
Wind direction Flow induced vibrations
NAFENS World Congress
vancouver Nay 2007
Dynamic response of structure without flow
1
NAFEMS World Congress
Vancouver May 2007
Fluid Velocity and Pressure Movies
At tip of wing
NAFEMS World Congress
Vancouver May 2007
Shear stress
xy
in wing
2
NAFEMS World Congress
Vancouver May 2007
Bio-medical multi-physics modelling:
the heart!
Heart a multi-physics system, featuring
interactions between:
- electro-chemical system
- fluid
- structure
Image from www.heartvalves.8m.com
NAFEMS World Congress
Vancouver May 2007
Geometry
2D model
Right ventricle
Blood
0.005m
Outlet Inlet
Wall
0.045m
0.01m 0.01m
0.08m
3
NAFEMS World Congress
Vancouver May 2007
Electro-fluid-structure interaction
Electrical
Structure
Mesh
dynamics
Fluid
flow
NAFEMS World Congress
Vancouver May 2007
Multi-potential heart electrical activity model:
comparison of results
PHYSICA
Clayton and Holden 02
Primary and secondary potentials Currents
1
NAFEMS World Congress
Vancouver May 2007
Coupling electrical field to structural mechanics
Assumption made that small strain model can
capture behaviour of heart wall
Dominant behaviour of wall is contraction/expansion
Shearing effects negligible
Elastic model
Change in potential results in a change in tension
in the heart wall
To model tension we introduce an electric strain
into structural mechanics equations
NAFEMS World Congress
Vancouver May 2007
Electric potential, deformation &
flow patterns
Results at various stages through a heart beat cycle
2
NAFENS World Congress
vancouver, Nay 2007
Parallel Multi-Physics
Modelling
NAFEMS World Congress
Vancouver May 2007
Exploiting parallel cluster technology:
the challenge
MpCCI and other filter
technologies
Upside enables
interaction at the code
dbase level
Downside all data
exchange must go via
filter and is a compute
bottleneck wrt
scalability on parallel
clusters
Code A
(CFD)
Code B
(FEA)
Filter tech:
Map onto
Parallel
cluster
Map onto
Parallel
cluster
BOTTLENECK BOTTLENECK
3
NAFEMS World Congress
Vancouver May 2007
Parallel Multi-Physics Framework
CAPlib JOSTLE
PHYS!CA
PDE Solver
Generic Parallel Calls Lib Nesh Partition
Simulations very Time Consuming need
Parallel capability
NAFEMS World Congress
Vancouver May 2007
Parallelisation approach
Partition of 3D unstructured mesh
by JOSTLE
Uses mesh partitioning SPMD
strategy with non-uniform
workload
Assumes a homogeneous load
balance across the mesh:
load balanced ( even no of cells per
node)
minimises sub-domain
interface elements
sub-domain connectivity
matches processor topology of the
parallel system
4
NAFEMS World Congress
Vancouver May 2007
Multi-physics Simulation parallel issues
Sub-domains have
specific physics so
partition must reflect this:
non-uniform load/node
Distinct physics uses
distinct discretisation
procedures:
secondary partitions
Sub-domains may change
as problem develops:
dynamic load balance
Solid mechanics
Fluid flow
Heat transfer
Strategy needs to address all the above issues
NAFEMS World Congress
Vancouver May 2007
Primary & secondary partitions
Primary & secondary
meshes
Good primary & poor
Secondary partition
Good primary &
Secondary partitions
from JOSTLE
5
NAFEMS World Congress
Vancouver May 2007
Parallel multi-physics: two level approach
Implement a generic parallel version
of Multi-physics code/ MDA codes
without regard to in-homogeneity of the
computational work over the mesh(es) defining
the analysis domain
Dump the load balancing into the
mesh (re)partitioning task -
JOSTLE_DLB
Process as straightforward as possible
JOSTLE
PHYS!CA
PDE Solver
Mesh Partition
NAFEMS World Congress
Vancouver May 2007
Metal Forming - Extrusion
Involves large scale
deformation of metal work-
piece through interaction
with one or more dies
Multi-physics problem
Flow/deformation of
work-piece
Heat transfer generated
by internal friction
Stress/strain in die(s)
6
NAFEMS World Congress
Vancouver May 2007
Mixed Eulerian-Lagrangian Approach
Workpiece
Eulerian mesh
Free-surface algorithm to track deformation
Non-Newtonian material model
Heat transfer plus energy generated by internal friction
Die
Lagrangian mesh
Mechanical behaviour coupled with:
Thermal behaviour in workpiece
Fluid traction load from workpiece
NAFEMS World Congress
Vancouver May 2007
Governing Equations - Extrusion
Coupled Thermo - mechanical problem
Heat transfer significant factor in deformation process
CFD
Non-Newtonian viscosity model Plastic Norton Hoff law
Heat Transfer - Friction between die and workpiece.
Free Surface - Van Leer method
CSM
Static equilibrium equation linear elastic solid.
Coupling at the workpiece/die boundary:
Die subject to fluid traction boundary condition.
Workpiece subject to a die velocity boundary condition.
Dynamic meshes GCL. Fluid velocity relative to mesh
movement.
7
NAFEMS World Congress
Vancouver May 2007
Extrusion through U-shaped die
4.76 mm
41.27 mm
47.62 mm
Initial diameter = 200mm
Bearing length = 2.5mm
Punch speed = 5.85E-3m/s
63220 elements
69507 nodes
Workpiece = 470 Workpiece = 470 C C
Die = Die = 450 450 C C
Air = 30 Air = 30 C C
NAFEMS World Congress
Vancouver May 2007
Temperature contours in extruding work-piece
8
NAFEMS World Congress
Vancouver May 2007
Effective stress contours and deformation of die
NAFEMS World Congress
Vancouver May 2007
Parallel results
13.43 6.1 16
10.92 7.5 12
8.03 10.2 8
4.48 18.3 4
1 81.9 1
Speed-up
Run time
(hours)
Processors
Itanium IA 64 cluster running Linux OS
Eight nodes, two 733MHz processors per node
Each node with 2 Gb memory & 2Gb swap space
Single phase mesh partitions on 16 processors
9
NAFEMS World Congress
Vancouver May 2007
Challenges
Multi-physics OK where
discretisation methods are
coherent
What about distinct
methods FE-BE can be
OK
Continuum-particulate
interaction fracturing
What happens when it
involves combustion, heat
transfer, fluid flows, etc
Can I do this scalably in
parallel?
Fracturing
NAFEMS World Congress
Vancouver May 2007
Conclusion
Multi-physics simulation is emerging in a commercially
supported manner
Most successful multi-physics is based upon loose or one-
way coupling even then, heroic computing
Close coupling in time and space another ball game - Key
here are procedures for time & space accurate simulations;
DFSI a key exemplar
Multi-physics essentially compute intensive leads to
challenge of parallel scalability for multi-physics
simulation tools
Can do for bespoke single software solutions, but for
multi-code components, not so clear!
Challenges for the future integrating components using
essentially distinctive model paradigms & solver strategies