<p>Finite element analysis (FEA) employs a science-based approach in which the complete machining process can be simulated and optimized before resorting to costly and time-consuming experimental trials. In this work, cutting coefficient of AISI 1045 steel will be estimated using finite element modelling using Arbitrary Lagrangian Eulerian formulation (ALE). The estimated values are then experimentally validated. A parametric study is carried out after in order to investigate how some cutting parameters can affect the cutting coefficients. The process parameters to be varied include feed rate, cutting speed, and cutting edge radius.</p> / Master of Applied Science (MASc)

Die Dynamik von elastischen Membranen, Kapseln und Schalen hat sich zu einem aktiven Forschungsgebiet in der simulationsgestützten Physik und Biologie entwickelt. Die dünne Oberfläche dieser elastischen Materialien ermöglicht es, sie effizient als Hyperfläche zu approximieren. Solche Oberflächen reagieren auf Dehnungen in Oberflächenrichtung und Verformungen in Normalenrichtung mit einer elastischen Kraft. Zusätzlich können Oberflächenspannungskräfte auftreten. In dieser Arbeit präsentieren wir eine neuartige Arbitrary Lagrangian-Eulerian (ALE) Methode um solche in (Navier-Stokes) Fluiden eingebetteten elastischen Schalen zu simulieren. Dadurch, dass das Gitter an die elastische Oberfläche angepasst ist, kombiniert die vorgeschlagene Methode hohe Genauigkeit mit Effizienz in der Berechnung der Lösungen. Folglich kann man die Simulationen mit einer verhältnismäßig geringen Gitterauflösung durchführen. Der Fokus dieser Arbeit liegt bei achsensymmetrischen Formen und Strömungen, wie sie bei vielen biophysikalischen Anwendungen zu finden sind. Neben einer allgemeinen dreidimensionalen Beschreibung formulieren wir achsensymmetrische Kräfte auf der Oberfläche, für welche wir eine Diskretisierung mit der Finite Differenzen Methode vorschlagen, welche an eine Finite-Elemente Methode für die umgebenden Fluide gekoppelt ist. Weiterhin entwickeln wir eine Strategie zur impliziten Kopplung der Kräfte, um Zeitschrittrestriktionen zu reduzieren. In verschiedenen numerischen Tests werden wir zeigen, dass akkurate Ergebnisse schon in einer Größenordnung von Minuten auf einer Single-Core CPU erreicht werden können. Die Methode wurde in drei aktuellen Anwendungen verwendet, wobei mindestens zwei davon nach unserer Kenntnis im Moment mit keiner anderen numerischen Methode simuliert werden können: Zunächst präsentieren wir Simulationen von biologischen Zellen, die im Zuge eines RT-DC (Real-Time Deformability Cytometry) Experiments durch einen schmalen mikrofluidischen Kanal advektiert und dabei verformt werden. Danach zeigen wir die Ergebnisse erster Simulationen der uniaxialen Kompression biologischer Zellen zwischen zwei parallelen Platten im Zuge eines AFM Experiments. Schließlich präsentieren wir Resultate erster Simulationen von neuartigen mikroschwimmenden Schalen, welche lediglich durch äußere Einflüsse (wie z.B. Ultraschall), zum Schwimmen angeregt werden können. / The dynamics of membranes, shells, and capsules in fluid flow has become an active research area in computational physics and computational biology. The small thickness of these elastic materials enables their efficient approximation as a hypersurface, which exhibits an elastic response to in-plane stretching and out-of-plane bending, possibly accompanied by a surface tension force. In this work, we present a novel arbitrary Lagrangian-Eulerian (ALE) method to simulate such elastic surfaces immersed in Navier-Stokes fluids. The method combines high accuracy with computational efficiency, since the grid is matched to the elastic surface and can therefore be resolved with relatively few grid points. The focus of this work is on axisymmetric shapes and flow conditions, which are present in a wide range of biophysical problems. Next to a general three-dimensional description, we formulate axisymmetric elastic surface forces and propose a discretization with surface finite-differences coupled to evolving finite elements. We further develop an implicit coupling strategy to reduce time step restrictions. Several numerical test cases show that accurate results can be achieved at computational times on the order of minutes on a single core CPU. Three state-of-the-art applications are demonstrated, where to our knowledge at least two of them cannot be simulated with any other numerical method so far. First, simulations of biological cells being advected through a microfluidic channel and therefore being deformed during an RT-DC (Real-Time Deformability Cytometry) experiment are presented. Then, the uniaxial compression of the cortex of a biological cell during an AFM experiment is investigated. Finally, we present the results of first simulations of the observed shape oscillations of novel microswimming shells which can be locomoted by exterior influences (e.g. ultrasound waves) only.

Modelling the full event of an underwater explosion (UNDEX) is complex and requires advanced modelling methods in order to achieve accurate responses. The process of an UNDEX includes a series of events that has to be considered. When a detonation is initiated, a shock-wave propagates and the rest products from the explosive material creates a gaseous bubble with high pressure which pulsates and impacts the surroundings. Reflections of the initial shock-wave can also appear if it hits the sea floor, water surface or other obstacles. There are different approaches how to numerically model the impact of an UNDEX on a structure, some with analytical approaches without a water domain and others where a water domain has to be modelled. This master’s thesis focuses on two modelling methods that are available in the finite element software LS-DYNA. The simpler method is called Sub-Sea Analysis (SSA) and does not require a water domain, thus it can be beneficial to use in an early design stage, or when only approximated responses are desired. To increase the accuracy, a more complex method called S-ALE can be used. By implementing this method, the full process of an UNDEX can be studied since both the fluid domain and explosive material are meshed. These methods are studied separately together with a combination of them. Another important aspect to be considered is that oscillations of a structure submerged in water differs from the behavior it has in air. Depending on the numerical method used, the impact of the water can be included. Natural frequencies of structures submerged in water are studied, how it changes and how the methods takes this into account. To verify the numerical models, experiments were executed with a cylindrical test object where the distance and weight of charge were altered through out the test series. It was found that multiple aspects affects the results from the experiments, that are not captured in the numerical models. These aspects have for instance to do with reflections, how accurate the test object is modelled and the damping effects of the water. It is concluded that the numerical models are sensitive when small charges and fragile structures are studied. High frequency oscillations were not triggered in the experiment but found for both methods. It should be further investigated if the methods are more accurate for larger charges and stronger structures. Experiments with larger water domain would also be beneficial to reduce effects from reflections, as well as a more accurate model of the cylinder in the simulations.

Interactions between three immiscible phases, including incompressible viscoelastic structures and fluids, form standard constellations for countless scenarios in natural science. The complexity of many such scenarios has motivated various research efforts in scientific computing. This work presents novel numerical approaches for two specific of these ternary fluid-structure interaction constellations. The potential of these approaches is demonstrated by diverse applications. First, a phase field model is developed describing the interaction between a fluid and a viscoelastic solid. For this purpose, a Navier-Stokes-Cahn-Hilliard system is considered together with a hyperelastic neo-Hookean model. Based on this, an arbitrary Lagrangian-Eulerian (ALE) method is implemented to simulate the indentation of the solid material in the context of atomic force microscopy, capable of predicting physical parameters. Next, the second approach is developed to describe the interaction between a two-phase fluid and a viscoelastic solid, where fluid and solid are defined on separate domains but aligned at the interface between them. The previously introduced phase field model is used to represent the fluid and an ALE method is used for the motion of the grid, where the fluid-solid interface moves with flow velocity. A unified system is solved in all subdomains, which includes both the balance of mass and momentum and the balance of forces at the fluid-solid interface. Simulations of static and dynamic soft wetting are subsequently presented, in particular a contact line moving over a substrate with oscillating stick-slip behavior. This work combines the advantages of phase field and ALE methods for meaningful simulations and emphasizes validity and numerical stability in all approaches.

A three-dimensional, parallel, finite volume solver which uses Roe&#039 / s upwind flux differencing scheme for spatial and Runge-Kutta explicit multistage time stepping scheme for temporal discretization on unstructured meshes is developed for the unsteady solution of external viscous flow around rotating bodies. The main aim of this study is to evaluate the aerodynamic dynamic stability derivative coefficients for rotating missile configurations. Arbitrary Lagrangian Eulerian (ALE) formulation is adapted to the solver for the simulation of the rotation of the body. Eigenvalues of the Euler equations in ALE form has been derived. Body rotation is simply performed by rotating the entire computational domain including the body of the projectile by means of rotation matrices. Spalart-Allmaras one-euqation turbulence model is implemented to the solver. The solver developed is first verified in 3-D for inviscid flow over two missile configurations. Then inviscid flow over a rotating missile is tested. Viscous flux computation algorithms and Spalarat-Allmaras turbulence model implementation are validated in 2-D by performing calculations for viscous flow over flat plate, NACA0012 airfoil and NLR 7301 airfoil with trailing edge flap. The ALE formulation is validated in 2-D on a rapidly pitching NACA0012 airfoil. Afterwards three-dimensional validation studies for viscous, laminar and turbulent flow calculations are performed on 3-D flat plate problem. At last, as a validation test case, unsteady laminar and turbulent viscous flow calculations over a spinning M910 projectile configuration are performed. Results are qualitatively in agreement with the analytical solutions, experimental measurements and previous studies for steady and unsteady flow calculations.

The aim of this study is to simulate the unsteady flow around rotating or oscillating airfoils. This will help to understand the rotor aerodynamics, which is essential in turbines and propellers. In this study, a pre-existing Euler solver with finite volume method that is developed in the Mechanical Engineering Department of Middle East Technical University (METU) is improved. This structured pre-existing code was developed for 2-D internal flows with Lax-Wendroff scheme. The improvement consist of firstly, the generalization of the code to external flow / secondly, implementation of first order Roe&rsquo / s flux splitting scheme and lastly, the implementation of rotation with the help of Arbitrary Lagrangian Eulerian (ALE) method. For the verification of steady and unsteady results of the code, the experimental and computational results from literature are utilized. For steady conditions, subsonic and transonic cases are investigated with different angle of attacks. For the verification of unsteady results of the code, oscillating airfoil case is used. The flow is assumed as inviscid, unsteady, adiabatic and two dimensional. The gravity is neglected and the air is taken as ideal gas. The developed code is run on computers housed in METU Mechanical Engineering Department Computational Fluid Dynamics High Performance Computing (CFD-HPC) Laboratory.

Finite element(FE) method has been used to model cutting process since 1970s. However, it requires special techniques to cope with the difficulties in simulating extremely large strain when compare to static or small deformation problems. With the advancement of FE techniques, researchers can now have a deeper insight of the mechanism of material flow and chip formation of metal cutting process. Even the stagnation effect of the workpiece material in front of the cutting edge radius can be captured by using FE techniques such as Remeshing and Arbitrary Lagrangian Eulerian(ALE) formulation. However most of this models are limited to plane strain assumption which means they are 2-dimensional. Although 3D models are existing in the literatures, most of them employ Remeshing technique which is very computationally intensive and has many critics regarding its accuracy due to its frequent remeshing and mapping process. The rest of the 3D models employ Lagrangian formulation. The 3D models by Lagrangian formulation have the same limitations and drawbacks as in 2D models, as it requires failure criteria and in most of the cases predefined partition surfaces are also required. ALE technique on the other hand resolves all the drawbacks of the other formulations, it not only inherits the advantages of the other techniques but also has its own unique advantages such as it can simulate a longer time span up to couple seconds more economically by fixing the number of elements used. Although it's commonly accepted that ALE formulation is superior to other formulations of techniques in modeling metal cutting process, its usage is only limited to 2D models. Limited 3D ALE metal cutting models is available in the literature. Thus the main objective of this research is to explore the possibility of building a 3D metal cutting model with ALE formulation. The reliability and limitations will also be studied. Furthermore, Couple Eulerian-Lagrangian(CEL) formulation is a recent developed formulation that has a lot of potential in modeling metal cutting process in 3D. It will be compared with ALE models to study its potential and limitations in modeling metal cutting process. A new frictional model will also be proposed, which suggests that the frictional phenomenon in metal cutting is a consolidated effect of both friction between material interface and shear yield of the workpiece material. This idea provide a brand new perspective of viewing the friction phenomenon of metal cutting compared to those existed models. / Thesis / Master of Science (MSc)

O fenômeno de molhamento, estudo de como um líquido se deposita em um sólido, apresenta problemas ainda em aberto, dos pontos de vista da modelagem física e da simulação numérica. O maior interesse acadêmico neste tipo de escoamento é a linha tríplice (ou linha de contato) formada da interação sólido-líquido-gás. A condição de contorno clássica de não escorregamento na interface líquido-sólido leva a uma singularidade no tensor de tensões nesta linha. Além disso, ainda não está estabelecido qual o melhor modelo para descrever o ângulo de contato formado entre a superfície livre e o substrato (o sólido). Neste trabalho, são discutidos métodos numéricos para a simulação de linhas de contato dinâmicas. Os efeitos da tensão superficial são estudados com a abordagem do princípio do trabalho virtual, o qual leva o problema à equações na formulação variacional, linguagem natural para o tratamento numérico com o método dos elementos finitos (FEM). O domínio é discretizado por uma malha não-estruturada de forma que as interfaces separadoras são explicitamente representadas pela malha. As derivadas temporais são tratadas em uma abordagem Lagrangeana-Euleriana arbitrária (ALE). Finalmente, são apresentados os resultados numéricos obtidos com o método ALE-FEM, discutindo alguns aspectos da sua convergência temporal e espacial. / Wetting phenomena, study of how of a liquid spreads out on a solid substrate, presents challenges both in physical modeling and in numerical simulation. The triple line (or contact line) formed by the solid-liquid-gas interaction has increasingly attracted the attention of the fluid dynamic community. The classical no-slip boundary condition on the liquid-solid interface leads to a singularity in the stress tensor at contact lines. Furthermore, there is no consensus on what the best model to describe the dynamics of the contact angle formed by the solid substrate and free surface. In this work, numerical methods for simulating dynamic contact lines are considered. The capillarity effects are studied in the approach of the virtual-work principle, which describes the problem in the variational formulation, natural language for numerical treatment with the finite element method (FEM). The domain is discretized by a dynamic unstructured mesh, where the separating interfaces are explicit represented by the mesh. Time derivatives present in the governing equations are treated with the arbitrary Lagrangian-Eulerian (ALE) framework. Finally, we discuss some temporal and spatial convergence issues ofthe ALE-FEM method.

Semi-solid thixoforming processes rely on a material microstructure made of globular solid grains more or less connected to each other, thus developing a solid skeleton deforming into a liquid phase. During processing, the material structure changes with the processing history due to the agglomeration of the particles and the breaking of the grains bonds. This particular evolutive microstructure makes semi-solid materials behave as solids at rest and as liquids during shearing, which causes a decrease of the viscosity and of the resistance to deformation while shearing. Thixoforming of aluminum and magnesium alloys is state of the art and a growing number of serial production lines are in operation all over the world. But there are only few applications of semi-solid processing of higher melting point alloys such as steel. This can partly be attributed to the high forming temperature combined with the intense high temperature corrosion that requires new technical solutions. However the semi-solid forming of steels reveals high potential to reduce material as well as energy consumption compared to conventional process technologies, such as casting and forging. Simulation techniques exhibit a great potential to acquire a good understanding of the semi-solid material process. Therefore, this work deals with the development of an appropriate constitutive model for semi-solid thixoforming of steel. The constitutive law should be able to simulate the complex rheology of semi-solid materials, under both steady-state and transient conditions. For example, the peak of viscosity at start of a fast loading should be reproduced. The use of a finite yield stress is appropriate because a vertical billet does not collapse under its own weight unless the liquid fraction is too high. Furthermore, this choice along with a non-rigid solid formalism allows predicting the residual stresses after cooling down to room temperature. Several one-phase material modeling have been proposed and are compared. Thermo-mechanical modeling using a thermo-elasto-viscoplastic constitutive law has been developed. The basic idea is to extend the classical isotropic hardening and viscosity laws to the non solid state by considering two non-dimensional internal parameters. The first internal parameter is the liquid fraction and depends on the temperature only. The second one is a structural parameter that characterizes the degree of structural build up in the microstructure. Those internal parameters can depend on each other. The internal parameters act on the the viscosity law and on the yield surface evolution law. Different formulations of viscosity and hardening laws have been proposed and are compared to each other. In all cases, the semi-solid state is treated as a particular case, and the constitutive modeling remains valid over the whole range of temperature, starting from room temperature to above the liquidus. These models are tested and illustrated by mean of several representative numerical applications.

La predicción precisa de los efectos producidos por el acoplamiento fluido estructura para cuerpos parcial o totalmente sumergidos, incluyendo superficies libres, es un problema de gran relevancia en la ingeniería naval así como en muchos otros campos del diseño de estructuras sometidas a la acción de fluidos.Las dificultades que se encuentran en la resolución de los problemas de interacción fluido estructura se deben principalmente a las siguientes causas:1. La dificultad de resolver numéricamente las ecuaciones de la dinámica de un fluido incompresible que, en general, si descartamos el caso más simple del modelo del flujo potencial, tienen un importante carácter no lineal. 2. Los obstáculos que se presentan al resolver la ecuación de la superficie libre, que constriñen el movimiento de las partículas a una superficie fluida de posición a priori desconocida.3. Las dificultades asociadas a la resolución del problema del movimiento de un cuerpo sumergido debido a las fuerzas de interacción, minimizando la deformación de los elementos de la malla y reduciendo, de esta manera, la necesidad del remallado.En la presente tesis se presenta un método estabilizado basado en el método de los elementos finitos que pretende solventar cada uno de los problemas anteriores. La metodología se basa en la modificación de las ecuaciones diferenciales de la dinámica de fluidos que gobiernan el flujo viscoso incompresible y el movimiento de la superficie libre, mediante la aplicación del método de cálculo finitesimal (FIC) propuesto en este trabajo.En el presente caso las ecuaciones modificadas son resueltas usando un esquema de pasos fraccionados semi-implícito y el método de los elementos finitos (FEM). El movimiento del cuerpo sumergido en el fluido debido a las fuerzas de interacción se calcula resolviendo un problema estructural dinámico, para el cual las fuerzas del fluido son las condiciones iniciales. Se incluye, además, un algoritmo para el movimiento de la malla debido a la deformación del dominio de cálculo. Este método minimiza la distorsión de la malla debida al movimiento del sólido rígido y al cambio de posición de la superficie libre. Este algoritmo se basa en la solución iterativa por el método de elementos finitos de un problema lineal, donde la malla de cálculo se considera un sólido elástico sometido a la deformación prescrita por el cambio en el dominio de cálculo. Las características de elasticidad del sólido, y en concreto su rigidez, se aplican de manera que los elementos que más se deforman tienen una rigidez mayor. Por último se presentan varios ejemplos de interés industrial, aplicación de la metodología propuesta en diferentes campos de la ingeniería naval.