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This document deals with the development of drilling tools by means of CAD and CAE technologies. At first, a brief overview of various design procedures of 3D drill models is presented, possibilities of measurement of force and moment loading during drilling are mentioned, a chip formation mechanism is briefly described and then a list of commonly used explicit (mesh) finite element methods used for cutting simulations is presented. A meshless SPH method have been selected for this work. Although it is able to handle the large deformations easily, it has been used for cutting simulations very rarely and only an orthogonal cutting simulations related information can be found in scientific databases. It has been demonstrated on the orthogonal cutting simulation of A2024-T351 alloy that was also the starting point for SPH simulation of drilling. The following is a decription of the design, simulation and prototyping of new drilling tools - drills with three and two cutting edges and an internal chip channel. This document is focused in detail on the variant with two cutting edges for which SPH drilling simulation has also been performed. Some drawbacks related to more precise chip simulation demands have been revealed, especially a rapid increase in number of SPH elements followed with prolongation of a computational time. Information related to the design of the drilling head with two cutting edges were then used to create the patent application.

L’objectif de cette thèse est le développement et l'extension de la méthode SPH pour l'analyse de structures de type coque, isotropes et composites multicouches soumises à des chargements dynamiques. Les différents verrouillages de la méthode SPH classique, tels que la non consistance, l'instabilité en traction, sont résolus par la méthode dite "Corrective Smoothed Particle Method", l'utilisation d'une Formulation Lagrangienne Totale et l'introduction de viscosité artificielle. Le modèle de coque basé sur la théorie de Reissner-Mindlin est adopté pour la modélisation des structures de coque épaisses en utilisant une seule couche de particules dans le plan moyen. La forme forte d’équations gouvernantes de coque sont discrétisées directement par la méthode SPH améliorée et résolues par un schéma explicite basé sur les différences finies centrées. Une extension de la méthode a été faite pour la modélisation d'impact de coques par des objets rigides à faible vitesse. La force de contact est calculée en utilisant la théorie de Hertz. Une dernière extension de la méthode concerne l'intégration du critère de rupture de Tsai-Wu pour la modélisation de la dégradation progressive pour les structures composites multicouches. / The objective of this thesis is the development and the extension of the SPH method for the analysis of isotropic and multilayered composite shell structures, undergoing dynamic loading. Major defects of the classical SPH method such as the lack of consistency, the tensile instability are solved by "Corrective Smoothed Particle Method", the use of the Total Lagrangian Formulation and artificial viscosity. Mindlin-Reissner Theory is employed for the modeling of thick shells, by using only one layer of particles in the mid-plane. The strong form of the governing equations for shell structures are discretized directly by the modified SPH method and solved using the central difference time integration scheme. An extension of the method has been introduced for the modeling of low-velocity impact of shells by rigid impactors. The contact force is calculated based on the Hertzian contact law. A last extension of the SPH method concerns the integration of Tsai-Wu failure criterion for the modeling of progressive degradation of multilayered structures.

This work presents the mathematical and computational aspects of a smooth dissipative particle dynamics with dynamic virtual particle allocation method (SDPD-DV) for modeling and simulation of mesoscopic fluids in wall-bounded domains. The SDPD-DV method is realized with fluid particles, boundary particles and dynamically allocated virtual particles near solid boundaries. The physical domain in SDPD-DV contains external and internal solid boundaries, periodic inlets and outlets, and the fluid region. The solid boundaries of the domain are represented with boundary particles which have an assigned position, wall velocity, and temperature upon initialization. The fluid domain is discretized with fluid particles placed in a global index. The algorithm for nearest neighbor particle search is based on a combination of the linked-cell and Verlet-list approaches and utilizes large rectangular cells for computational efficiency. The density model of a fluid particle in the proximity of a solid boundary includes the contribution from the virtual particles in its truncated support domain. The thermodynamic properties of a virtual particle are identical to those of the corresponding fluid particle. A periodic boundary particle allocation method is used at periodic inlets and outlets. Models for the conservative and dissipative forces on a fluid particle in the proximity of a solid boundary are presented and include the contributions of the virtual particles in its truncated support domain. The integration of the fluid particle position and momentum equations is accomplished with an implementation of the velocity-Verlet algorithm. The integration is supplemented by a bounce-forward algorithm in cases where the virtual particle force model is not able to prevent particle penetration. The integration of the entropy equation is based on the Runge-Kutta scheme. In isothermal simulations, the pressure of a fluid particle is obtained by an artificial compressibility formulation for liquids and the ideal gas law for compressible fluids. Sampling methods used for particle properties and transport coefficients in SDPD-DV are presented. The self-diffusion coefficient is obtained by an implementation of the generalized Einstein and the Green-Kubo relations. Field properties are obtained by sampling SDPD-DV outputs on a post-processing grid that allows harnessing the particle information on desired spatio-temporal scales. The isothermal (without the entropy equation) SDPD-DV method is verified and validated with simulations in bounded and periodic domains that cover the hydrodynamic and mesoscopic regimes. Verification is achieved with SDPD-DV simulations of transient, Poiseuille, body-force driven flow of liquid water between plates separated. The velocity profiles from the SDPD-DV simulations are in very good agreement with analytical estimates and the field density fluctuation near solid boundaries is shown to be below 5%. Additional verification involves SDPD-DV simulations of transient, planar, Couette liquid water flow. The top plate is moving and separated from the bottom stationary plate. The numerical results are in very good agreement with the analytical solutions. Additional SDPD-DV verification is accomplished with the simulation of a body-force driven, low-Reynolds number flow of water over a cylinder of radius R=0.02m. The SDPD-DV field velocity and pressure are compared with those obtained by FLUENT. An extensive set of SDPD-DV simulations of liquid water and gaseous nitrogen in mesoscopic periodic domains is presented. For the SDPD-DV simulations of liquid water the mass of the fluid particles is varied between 1.24 and 3.3e-7 real molecular masses and their corresponding size is between 1.08 and 323 physical length scales. For SDPD-DV simulations of gaseous nitrogen the mass of the fluid particles is varied between 6.37e3and 6.37e6 real molecular masses and their corresponding size is between 2.2e2 and 2.2e3 physical length scales. The equilibrium states are obtained and show that the particle speeds scale inversely with particle mass (or size) and that the translational temperature is scale-free. The self-diffusion coefficient for liquid water is obtained through the mean-square displacement and the velocity auto-correlation methods for the range of fluid particle masses (or sizes) considered. Various analytical expressions for the self-diffusivity of the SDPD fluid are developed in analogy to the real fluid. The numerical results are in very good agreement with the SDPD-fluid analytical expressions. The numerical self-diffusivity is shown to be scale dependent. For fluid particles approaching asymptotically the mass of the real particle the self-diffusivity is shown to approach the experimental value. The Schmidt numbers obtained from the SDPD-DV simulations are within the range expected for liquid water. The SDPD-DV method (with entropy) is verified and validated with simulations with an extensive set of simulations of gaseous nitrogen in mesoscopic, periodic domains in equilibrium. The simulations of N2(g) are performed in rectangular domains. The self-diffusion coefficient for N2(g) at equilibrium states is obtained through the mean-square displacement for the range of fluid particle masses (or sizes) considered. The numerical self-diffusion is shown to be scale dependent. The simulations show that self-diffusion decreases with increasing mass ratio. For a given mass ratio, increasing the smoothing length, increases the self-diffusion coefficient. The shear viscosity obtained from SDPD-DV is shown to be scale free and in good agreement with the real value. We examine also the effects of timestep in SDPD-DV simulations by examining thermodynamic parameters at equilibrium. These results show that the time step can lead to a significant error depending on the fluid particle mass and smoothing length. Fluctuations in thermodynamic variables obtained from SDPD-DV are compared with analytical estimates. Additional verification involves SDPD-DV simulations of steady planar thermal Couette flow of N2(g). The top plate at temperature T1 =330K is moving at Vxw =30m/s and is separated by 10-4 m from the bottom stationary plate at T2=300K. The SDPD-DV velocity and temperature fields are in excellent agreement with those obtained by FLUENT.

Incompressible free-surface flows involving highly complex and violent phenomena are of great importance to the engineering industry. Applications such as breaking-wave impacts, fluid-structure interaction, and sloshing tanks demand an accurate and noise-free pressure field, and require large-scale simulations involving millions of computation points. This thesis addresses the need with the novel use of a graphics processing unit (GPU) to accelerate the incompressible smoothed particle hydrodynamics (ISPH) method for highly non-linear and violent free-surface flows using millions of particles in three dimensions. Compared to other simulation techniques, ISPH is robust in predicting a highly accurate pressure field, through the solution of a pressure Poisson equation (PPE), whilst capturing the complex behaviour of violent free-surface flows. However, for large-scale engineering applications the solution of extremely large PPE matrix systems on a GPU presents multiple challenges: constructing a PPE matrix every time step on the GPU for moving particles, overcoming the GPU memory limitations, establishing a robust and accurate ISPH solid boundary condition suitable for parallel processing on the GPU, and exploiting fast linear algebra GPU libraries. A new GPU-accelerated ISPH algorithm is presented by converting the highly optimised weakly-compressible SPH (WCSPH) code DualSPHysics and combining it with the open-source ViennaCL linear algebra library for fast solutions of the ISPH PPE. The challenges are addressed with new methodologies: a parallel GPU algorithm for population of the PPE matrix, mixed precision storage and computation, and extension of an existing WCSPH boundary treatment for ISPH. Taking advantage of a GPU-based algebraic multigrid preconditioner for solving the PPE matrix required modification for ISPH's Lagrangian particle system. The new GPU-accelerated ISPH solver, Incompressible-DualSPHysics, is validated through a variety of demanding test cases and shown to achieve speed ups of up to 25.3 times and 8.1 times compared to single and 16-threaded CPU computations respectively. The influence of free-surface fragmentation on the PPE matrix solution time with different preconditioners is also investigated. A profiling study shows the new code to concentrate the GPU's processing power on solving the PPE. Finally, a real-engineering 3-D application of breaking focused-wave impacting a surface-piercing cylindrical column is simulated with ISPH for the first time. Extensions to the numerical model are presented to enhance the accuracy of simulating wave-structure impact. Simulations involving over 5 million particles show agreement with experimental data. The runtimes are similar to volume-of-fluid and particle-in-cell solvers running on 8 and 80 processors respectively. The 3-D model enables post-processing analysis of the wave mechanics around the cylinder. This study provides a substantial step for ISPH. Incompressible-DualSPHysics achieves resolutions previously too impractical for a single device allowing for the simulation of many industrial free-surface hydrodynamic applications.

Ce travail de thèse porte sur l’étude numérique de la propagation d’ondes de choc dans les écoulements compressibles multiphasiques et en interaction (fluide-structure). Deux approches sont étudiées pour la résolution numérique de la partie fluide : L’approche ALE (Arbitrary Lagrangian Eulerian) et l’approche lagrangienne SPH (Smoothed Particle Hydrodynamics) ; la partie structure, quant à elle, est résolue par une approche classique EF (Éléments finis). L’étude des méthodes ALE et SPH constituent les deux principaux axes de recherche. La problématique des coups de bélier dans l’ingénierie nucléaire est abordée dans cette thèse. Lors d’un coup de bélier, les nombreuses réflexions d’ondes de choc dans les tuyauteries nucléaires peuvent faire baisser la pression de l’eau en dessous de sa pression de saturation et générer localement de la cavitation. Le modèle HEM (Homogeneous Equilibrium Model) de changement de phase proposé par Saurel et al. (1999) à trois équations est étudié et appliqué aux coups de bélier. Les résultats obtenus sont comparés aux données expérimentales. Malgré l’utilisation des techniques de renormalisation en SPH, des instabilités (oscillations numériques) se développent à l’interface entre les particules de matériaux différents. Ces instabilités restreignent l’utilisation des schémas SPH classiques pour des problèmes à faible ratio de densité. Afin de résoudre les problèmes de choc, le schéma proposé par Hu et Adams (2006) est adapté au régime fortement compressible en considérant le couplage entre la densité et la longueur de lissage. Les différents schémas SPH sont comparés entre eux pour les problèmes de chocs multiphasiques en 1-D et 2-D. Les résultats SPH sont validés avec la solution exacte pour les problèmes 1-D et la solution ALE pour les problèmes 2-D. / This thesis focuses on the numerical study of the propagation of shock waves in compressible multiphase flows and fluid structure interaction. Two approaches are being studied for the numerical solution of the fluid part: the ALE approach (Arbitrary Lagrangian Eulerian) and the Lagrangian SPH (Smoothed Particle Hydrodynamics) approach; while the structure part is solved by a conventional FE (Finite Element). The numerical investigation of the ALE and SPH methods are the two main areas of research.Water Hammers phenomena occuring in nuclear industries are investigated in this thesis. During a Water Hammer, the shock waves reflections in nuclear piping may drop locally the water pressure below its saturation pressure and generate cavitation. The three equations HEM (Homogeneous Equilibrium Model) phase change model proposed by Saurel et al. (1999) is studied and applied to solve water hammers. The obtained results are compared with experimental data. Despite the use of renormalization techniques in SPH, instabilities (numerical oscillations) are developed at the interface between particles from different materials. These instabilities restrict the use of traditional SPH schemes to problems with low density ratio. In order to solve the shock problems in the compressible regime, the scheme originally proposed by Hu and Adams (2006) is adapted to fully compressible regime (FC-SPH) by considering the coupling between the density and the smoothing length. The different SPH schemes are compared for 1-D and 2-D multiphase shock problems. Validation is performed in comparison with exact solutions for 1-D problems and ALE solution for 2-D problems.

The effect of vegetation on the dissipation of waves is important in understanding the vegetation's role in protecting coastal communities during extreme events such as hurricanes and tsunamis. Numerical modeling makes it possible to study the flow through vegetation fields, but it is important to understand the flow dynamics around one piece of vegetation and validate the numerical model used, before the dynamics of an entire vegetated patch can be modeled and understood. This project validated GPUSPH, a Lagrangian mesh-free numerical model, by determining the optimal characteristics to obtain accurate simulations for flow through a flume with and without an obstruction. The validation of GPUSPH and determination of optimal characteristics was accomplished by varying model particle spacing, sub-particle scale (SPS) turbulence inclusion in the conservation of momentum equation, and kernel weighting function for two test cases. The model particle spacing sets the initial distance between the moving grid points, known as particles, in the system. The SPS turbulence term is intended to account for turbulence generated at the sub-particle scale between the particles. The kernel weighting functions used are the quadratic kernel and the cubic spline kernel. These kernels determine how much influence surrounding particles have on the flow characteristics of an individual particle. The numerical results of these tests were compared with experimental results to obtain conclusions about the accuracy of these simulations. Based on comparisons with experimental velocities and forces, the optimal particle spacing was found to occur when the number of particles was in the high 100,000s for single precision calculations, or mid-range capabilities, for the hardware used in this project. The sub-particle scale turbulence term was only necessary when there was large-scale turbulence in the system and created less accurate results when there was no large-scale turbulence present. There was no definitive conclusion regarding the best kernel weighting function because neither kernel had overall more accurate results than the other. Based on these conclusions, GPUSPH was shown to be a viable option for modeling free-surface flows for certain conditions concerning the particle spacing and the inclusion of the subparticle scale turbulence term.

Fluid simulations are computationally intensive and therefore time consuming and expensive. In the field of visual effects, it is imperative that artists be able to efficiently move through iterations of the simulation to quickly converge on the desired result. One common fluid simulation technique is the Smoothed Particle Hydrodynamics (SPH) method. This method is highly parellelizable. I have implemented a method to integrate a Graphics Processor Unit (GPU) accelerated SPH capability into the 3D software package Houdini. This helps increase the speed with which artists are able to move through these iterations. This approach is extendable to allow future accelerations of the algorithm with new SPH techniques. Emphasis is placed on the infrastructure design so it can also serve as a guideline for both GPU programming and integrating custom code with Houdini.

A machining process is one of the most common techniques used to remove material in order to create a final product. Most studies on mechanisms of cutting are performed under the assumption that the studied material is isotropic, homogeneous and continuous. One important feature of material- its anisotropyis linked to its crystallographic nature, which is usually ignored in machining studies. A crystallographic orientation of a workpiece material exerts a great influence on the chip-formation mechanism. Thus, there is a need for developing fundamental understanding of material's behaviour and material removal processes. While the effect of crystallographic orientation on cutting-force variation is extensively reported in the literature, the development of the single crystal machining models is somewhat limited.

Submitted by WEIXIAN CHEN null (wxchen.hunnu@gmail.com) on 2017-09-06T22:13:17Z No. of bitstreams: 1 WEI_XIAN.pdf: 1543145 bytes, checksum: 474b2e3c1648d156e0fc93d494d26580 (MD5) / Approved for entry into archive by Monique Sasaki (sayumi_sasaki@hotmail.com) on 2017-09-11T19:53:10Z (GMT) No. of bitstreams: 1 chen_w_me_guara.pdf: 1543145 bytes, checksum: 474b2e3c1648d156e0fc93d494d26580 (MD5) / Made available in DSpace on 2017-09-11T19:53:10Z (GMT). No. of bitstreams: 1 chen_w_me_guara.pdf: 1543145 bytes, checksum: 474b2e3c1648d156e0fc93d494d26580 (MD5) Previous issue date: 2017-08-30 / Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP) / Nesta dissertação, investigamos o algoritmo numérico conhecido como hidrodinâmicos de Partículas Suavizadas (SPH). O algoritmo de interpolação SPH é amplamente utilizado para equações diferenciais e para aplicações como problemas em colisões de íons pesados, por exemplo, modelo Landau unidimensional e expansão transveral de escala longitudinal. Propriedades importantes, precisão, eficiência e estabilidades, são discutidas. Como SPH é um método sem malha, os méritos e desvantagens comparados com os métodos baseados em grade anteriores são resumidos. Para colisão de alta energia, o sistema composto pode ser modelado pela hidrodinâmica. Em particular, a equação de Euler e sua versão relativística são abordadas. Além do método SPH convencional, o método de partículas finitas (FPM), que faz uso da expansão da série Taylor de funções suaves desconhecidas, também é investigado. Para o modelo Landau unidimensional, ambos os algoritmos são aplicados e os resultados são comparados. Devido à melhor precisão do FPM, a equação de movimento hidrodinâmica correspondente é derivada. Mostramos que a equação de movimento derivada garante uma melhor consistência das partículas. Também foram feitos esforços no desenvolvimento de programas para estudar a solução numérica do modelo hidrodinâmico de Landau. Escrevemos alguns programs curtos em c++ para calcular numericamente a evolução temporal do modelo de Landau. Os resultados são então comparados aos da abordagem analítica. Além disso, o código baseado no algoritmo SPH padrão é modificado para investigar o esquema FPM. / In this dissertation, we investigate the numerical algorithm known as the Smoothed Particle Hydrodynamics (SPH). The SPH interpolation algorithm are widely used for partial differential equations and for applications such as problems in heavy ion collisions for instance one dimensional Landau model and transverse expansion under a longitudinal scaling expansion. Important properties accuracy, efficiency, stability are discussed. As SPH IS a mesh free method, the merits and drawbacks comparing with previous grid based methods are summarized. For high energy collision, the compound system can be modeled by hydrodynamics. In particular, the Euler equation and its relativistic version are addressed. Besides the conventional SPH method, the finite particle method (FPM) which makes use of the Taylor series expansion of unknown smooth functions is also investigated. For the one dimensional Landu model, both algorithms are applied and results are compared. Owing to the better accuracy of the FPM, the corresponding hydrodynamic equation of motion is derived. We show that the derived equation of motion guarantees better particle consistency. Efforts have also been made in developing programs to study the numerical solution of Landau’s hydrodynamical model. We write some short programs in c++ to numerically calculate the temporal evolution of Landau’s model. The results are then compared to those of the analytic approach. Moreover the code based on the standard SPH algorithm is modified to investigate FPM scheme. / FAPESP: 2015/06212-5