Advanced Modeling and Simulation in Engineering Sciences最新文献

Prior to any numerical development, the paper objective is to answer first to a fundamental question: what is the mathematical form of the most general data-driven constitutive model for stable materials, taking maximum account of knowledge from physics and materials science? Here we restrict ourselves to elasto-(visco-)plastic materials under the small displacement assumption. The experimental data consists of full-field measurements from a family of tested mechanical structures. In this framework, a general data-driven approach is proposed to learn the constitutive model (in terms of thermodynamic potentials) from data. A key element that defines the proposed data-driven approach is a tool: the Constitutive Relation Error (CRE); the data-driven model is then the minimizer of the CRE. A notable aspect of this procedure is that it leads to quasi-explicit formulations of the optimal constitutive model. Eventually, a modified Constitutive Relation Error is introduced to take measurement noise into account.

Computational modeling of the melt pool dynamics in laser-based powder bed fusion metal additive manufacturing (PBF-LB/M) promises to shed light on fundamental mechanisms of defect generation. These processes are accompanied by rapid evaporation so that the evaporation-induced recoil pressure and cooling arise as major driving forces for fluid dynamics and temperature evolution. The magnitude of these interface fluxes depends exponentially on the melt pool surface temperature, which, therefore, has to be predicted with high accuracy. The present work utilizes a diffuse interface finite element model based on a continuum surface flux (CSF) description of interface fluxes to study dimensionally reduced thermal two-phase problems representative for PBF-LB/M in a finite element framework. It is demonstrated that the extreme temperature gradients combined with the high ratios of material properties between metal and ambient gas lead to significant errors in the interface temperatures and fluxes when classical CSF approaches, along with typical interface thicknesses and discretizations, are applied. It is expected that this finding is also relevant for other types of diffuse interface PBF-LB/M melt pool models. A novel parameter-scaled CSF approach is proposed, which is constructed to yield a smoother temperature field in the diffuse interface region, significantly increasing the solution accuracy. The interface thickness required to predict the temperature field with a given level of accuracy is less restrictive by at least one order of magnitude for the proposed parameter-scaled approach compared to classical CSF, drastically reducing computational costs. Finally, we showcase the general applicability of the parameter-scaled CSF to a 3D simulation of stationary laser melting of PBF-LB/M considering the fully coupled thermo-hydrodynamic multi-phase problem, including phase change.

In recent years, machine learning (ML) has had a great impact in the area of non-intrusive, non-linear model order reduction (MOR). However, the offline training phase often still entails high computational costs since it requires numerous, expensive, full-order solutions as the training data. Furthermore, in state-of-the-art methods, neural networks trained by a small amount of training data cannot be expected to generalize sufficiently well, and the training phase often ignores the underlying physical information when it is applied with MOR. Moreover, state-of-the-art MOR techniques that ensure an efficient online stage, such as hyper reduction techniques, are either intrusive or entail high offline computational costs. To resolve these challenges, inspired by recent developments in physics-informed and physics-reinforced neural networks, we propose a non-intrusive, physics-informed, two-tier deep network (TTDN) method. The proposed network, in which the first tier achieves the regression of the unknown quantity of interest and the second tier rebuilds the physical constitutive law between the unknown quantities of interest and derived quantities, is trained using pretraining and semi-supervised learning strategies. To illustrate the efficiency of the proposed approach, we perform numerical experiments on challenging non-linear and non-affine problems, including multi-scale mechanics problems.

We present accurate and mathematically consistent formulations of a diffuse-interface model for two-phase flow problems involving rapid evaporation. The model addresses challenges including discontinuities in the density field by several orders of magnitude, leading to high velocity and pressure jumps across the liquid-vapor interface, along with dynamically changing interface topologies. To this end, we integrate an incompressible Navier-Stokes solver combined with a conservative level-set formulation and a regularized, i.e., diffuse, representation of discontinuities into a matrix-free adaptive finite element framework. The achievements are three-fold: First, we propose mathematically consistent definitions for the level-set transport velocity in the diffuse interface region by extrapolating the velocity from the liquid or gas phase. They exhibit superior prediction accuracy for the evaporated mass and the resulting interface dynamics compared to a local velocity evaluation, especially for strongly curved interfaces.Second, we show that accurate prediction of the evaporation-induced pressure jump requires a consistent, namely a reciprocal, density interpolation across the interface, which satisfies local mass conservation. Third, the combination of diffuse interface models for evaporation with standard Stokes-type constitutive relations for viscous flows leads to significant pressure artifacts in the diffuse interface region. To mitigate these, we propose to introduce a correction term for such constitutive model types. Through selected analytical and numerical examples, the aforementioned properties are validated. The presented model promises new insights in simulation-based prediction of melt-vapor interactions in thermal multiphase flows such as in laser-based powder bed fusion of metals.