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Finite element modelling and experimental validation of two-roller vertical forward flow forming process of EN36B steel EN36B钢双辊垂直正向流成形过程的有限元建模与实验验证
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-11-13 DOI: 10.1016/j.advengsoft.2025.104063
Acar Can Kocabıçak , Kyle Nelson , Saeed Althamer , Senai Yalçınkaya , Gregor Kosec , Lihua Wang , Magd Abdel Wahab
Flow forming is a high-precision metal forming process used to produce thin-walled, rotationally symmetric components with enhanced mechanical properties. This study investigates the two-roller vertical forward flow forming process for EN36B steel through Finite Element Analysis (FEA) using FORGE® NxT 4.0, complemented by experimental validation. Material properties of EN36B steel, including elasticity, thermal, physical, and plasticity characteristics, were modelled with JmatPro software to ensure accurate simulations. Experimental trials included microstructural characterisation, hardness testing, surface roughness evaluation, and twist measurements to validate the numerical model. The FEA simulations provided critical insights into key process parameters such as Von Mises stress, strain, Latham-Cockroft damage, and force dynamics. Defects such as bulging and material build-up were effectively predicted and modelled. Dimensional accuracy was assessed using 3D GOM scanning, revealing a maximum thickness error of 0.3 mm. Discrepancies in force measurements between simulations and experiments were minimal, with deviations of 6.5 % for radial forces and 2.5 % for axial forces. Surface roughness improved significantly, with values decreasing from 2.1 μm Ra to 0.7 μm Ra after vertical forward flow forming.
Furthermore, the hardness increased from 186 HV to 260 MPa (around 40 %) after the forming due to the work hardening process with plasticity. Tensile stress of the workpiece increased from 620 MPa to 880 MPa without an additional heat treatment process. Due to the roller's high force on the workpiece's outer surface, the hardness testing revealed a maximum value of 279 HV on the outer surface, reducing to a minimum of 236 HV closer to the inner surface. The hardness error between FEA and experimental results is around 2 %. Electron Backscatter Diffraction (EBSD) analysis indicated higher grain deformation at the outside surface compared to the middle and inner surface of the flow-formed tube. The vertical forward flow forming process reached a maximum temperature of approximately 200 °C, which was efficiently managed through water cooling. The study highlights the utility of Arbitrary Lagrangian-Eulerian (ALE) formulations and remeshing techniques in simulating complex deformation patterns. These methods provide critical insights for optimising the flow forming process and advancing the manufacture of EN36B steel components.
流动成形是一种高精度的金属成形工艺,用于生产具有增强机械性能的薄壁、旋转对称部件。采用FORGE®NxT 4.0软件对EN36B钢的双辊垂直正向流成形过程进行了有限元分析,并进行了实验验证。利用JmatPro软件对EN36B钢的材料性能进行建模,包括弹性、热、物理和塑性特性,以确保模拟的准确性。实验包括微观组织表征、硬度测试、表面粗糙度评估和捻度测量来验证数值模型。有限元模拟提供了关键工艺参数的关键见解,如Von Mises应力、应变、Latham-Cockroft损伤和力动力学。缺陷,如胀形和材料堆积有效地预测和建模。使用3D GOM扫描评估尺寸精度,显示最大厚度误差为0.3 mm。模拟和实验之间的力测量差异很小,径向力的偏差为6.5%,轴向力的偏差为2.5%。垂直正向流动成形后,表面粗糙度从2.1 μm Ra降至0.7 μm Ra。成形后的硬度由186hv提高到260mpa(约40%),这是由于塑性加工硬化过程。工件的拉伸应力从620 MPa增加到880 MPa,无需额外的热处理工艺。由于滚轮对工件外表面施加较大的力,硬度测试显示,工件外表面的硬度最大值为279 HV,靠近工件内表面的硬度最小值为236 HV。有限元分析结果与实验结果的硬度误差在2%左右。电子背散射衍射(EBSD)分析表明,流动成形管的外表面晶粒变形比中、内表面大。垂直正向流动成形过程的最高温度约为200℃,通过水冷却有效地控制了这一温度。该研究强调了任意拉格朗日-欧拉(ALE)公式和重网格技术在模拟复杂变形模式中的实用性。这些方法为优化流动成形工艺和推进EN36B钢部件的制造提供了关键的见解。
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引用次数: 0
Research on vibrational characteristics of joined spherical- conical-cylindrical shells with multiple annular plates 多环板连接球-锥-圆柱壳振动特性研究
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-11-13 DOI: 10.1016/j.advengsoft.2025.104059
Zhou Huang , Xianjie Shi , Peng Zuo
A dynamic analysis model is developed to investigate the free vibration characteristics of a spherical-conical-cylindrical shell-circular plate coupling structure (SCCCCS). First, within the framework of the first-order shear deformation theory, the structural displacement function for a unified analysis model of revolving plate-shell structures is derived using spectro-geometric method. The artificial virtual spring technique is then applied to equivalently simulate the boundary and coupling conditions. The Ritz method is employed to solve the energy functional, resulting in the dynamic equation governing the SCCCCS analytical model. Numerical verification of the model's reliability and accuracy is performed by comparing its results with those obtained from the finite element method over a wide frequency range. A parameterized study on the dynamic characteristics of the SCCCCS under arbitrary boundary conditions is also conducted, considering various relevant parameters. The results indicate that both the semi-vertex angle of the conical shell and the coupling position of the circular plate significantly influence the structural stiffness of the SCCCCS, thereby affecting the variation of its frequency characteristics.
建立了球-圆锥-圆柱壳-圆板耦合结构的动力学分析模型,研究了该结构的自由振动特性。首先,在一阶剪切变形理论的框架下,利用光谱几何方法推导了旋转板壳结构统一分析模型的结构位移函数。然后应用人工虚拟弹簧技术等效模拟边界和耦合条件。采用里兹法求解能量泛函,得到控制SCCCCS解析模型的动力学方程。在较宽的频率范围内,通过与有限元法计算结果的比较,对模型的可靠性和精度进行了数值验证。考虑各种相关参数,对任意边界条件下SCCCCS的动态特性进行了参数化研究。结果表明,锥形壳的半顶角和圆板的耦合位置都会显著影响SCCCCS的结构刚度,从而影响其频率特性的变化。
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引用次数: 0
Feature-preserving mesh generation and simulation for implicitly represented lattice structures 隐式表示晶格结构的特征保留网格生成与仿真
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-11-12 DOI: 10.1016/j.advengsoft.2025.104065
Zhen Liu, Liang Xia
Lattice structures have attracted extensive research interest due to their hierarchical architecture and multi-functional properties, enabling unprecedented design flexibility across diverse engineering fields. In general, lattice structure modeling employs two primary methods: boundary representation (B-rep) and implicit representation. The latter is distinguished by its ability to generate lattice structures with more intricate geometries and more diverse functions compared to the former. However, the generated surface mesh the implicitly represented lattice structures is accomplished by feature distortion, non-manifold meshes, and self-intersecting meshes. This not only results in the failure of the generation of body-fitted meshes for finite element analysis (FEA) but also render the performance of additive manufacturing (AM) using the STL model built from the surface mesh impossible. To address these challenges, this work proposes a novel framework of feature-preserving meshing strategies by extending the dual contouring algorithm. The enhanced algorithm outperforms the dual contouring algorithm by ensuring generated surface meshes strictly adhere to topological validity requirements (manifold, closed, oriented), completely eliminating self-intersections, and faithfully preserving sharp geometric features. Subsequently, the remeshing of the surface mesh is performed to optimize the shape and reduce the count of triangles with preserved sharp geometric features, followed by the generation of body-fitted tetrahedral meshes, as depicted in Fig. 1. Finally, the proposed closed-loop mesh generation workflow generates a finite element (FE) model in the standard .inp file format, ensuring compatibility with commercial computational mechanics software (e.g., ABAQUS, ANSYS). Numerical examples show that the proposed meshing workflow is feasible and effective.
晶格结构由于其分层结构和多功能特性而引起了广泛的研究兴趣,在不同的工程领域实现了前所未有的设计灵活性。一般来说,网格结构建模主要采用两种方法:边界表示(B-rep)和隐式表示。与前者相比,后者的特点是能够生成具有更复杂几何形状和更多样化功能的晶格结构。然而,隐式表示的点阵结构生成的表面网格是通过特征畸变、非流形网格和自相交网格来完成的。这不仅会导致生成用于有限元分析(FEA)的体贴合网格的失败,而且还会使使用从表面网格构建的STL模型的增材制造(AM)的性能变得不可能。为了解决这些挑战,本工作通过扩展双轮廓算法提出了一种新的特征保持网格策略框架。增强算法通过确保生成的曲面网格严格遵守拓扑有效性要求(流形、封闭、定向),完全消除自交,忠实地保留尖锐的几何特征,优于双轮廓算法。随后,对表面网格进行重新网格划分,优化形状,减少保留尖锐几何特征的三角形数量,然后生成贴体四面体网格,如图1所示。最后,提出的闭环网格生成工作流生成标准中的有限元模型。inp文件格式,确保与商业计算力学软件(如ABAQUS, ANSYS)的兼容性。数值算例表明,所提出的网格划分流程是可行和有效的。
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引用次数: 0
A unified computational tool for residual stress reconstruction in surface-treated, large-scale components with arbitrary geometries using the eigenstrain method 一个统一的计算工具,用于残余应力重建的表面处理,大规模部件与任意几何使用特征应变方法
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-11-08 DOI: 10.1016/j.advengsoft.2025.104050
Ahmed Slimen , Rabï Ben Sghaier
Accurate quantification of residual stresses (RS) is essential to maintaining the structural integrity, durability, and performance of engineering components. Conventional approaches—including experimental techniques and process modeling—often suffer from limitations such as sparse data availability, high computational expense, and demanding material characterization requirements. In contrast, the eigenstrain method has emerged as a powerful alternative, enabling efficient RS reconstruction via linear elastic finite element analysis (FEA), while inherently satisfying equilibrium and compatibility conditions with minimal experimental input.
Despite its theoretical appeal, the practical application of eigenstrain-based methods—particularly for large-scale engineering components with complex geometries—has been limited by computational demands, lack of native implementation in commercial FEA platforms, and dependence on third-party software. These constraints fragment workflows, increase susceptibility to errors, and hinder broader adoption, highlighting the need for a unified computational framework.
EigenRec3D addresses this gap by providing a fully integrated platform for reconstructing residual stress fields in arbitrary two- and three-dimensional geometries via the eigenstrain method. Implemented entirely within the ANSYS® APDL environment through advanced scripting, it eliminates external dependencies while ensuring computational robustness. Its modular design and intuitive graphical interface streamline setup, minimize user intervention, and enhance accessibility for both research and industrial applications.
The tool’s capability is validated through case studies involving large-scale, surface-treated components of arbitrary shape, demonstrating accuracy, scalability, and readiness for deployment. EigenRec3D offers a pathway for integration into advanced manufacturing workflows, including additive manufacturing.
准确量化残余应力对保持工程构件的结构完整性、耐久性和性能至关重要。传统的方法——包括实验技术和过程建模——经常受到诸如稀疏的数据可用性、高计算费用和苛刻的材料表征要求等限制。相比之下,特征应变法已经成为一种强大的替代方法,通过线性弹性有限元分析(FEA)实现有效的RS重建,同时以最小的实验输入内在地满足平衡和相容性条件。尽管在理论上具有吸引力,但基于特征应变的方法的实际应用——特别是对于具有复杂几何形状的大型工程部件——受到计算需求的限制,缺乏商业有限元平台的本地实现,以及对第三方软件的依赖。这些约束使工作流片段化,增加了对错误的敏感性,并阻碍了更广泛的采用,突出了对统一计算框架的需求。EigenRec3D通过提供一个完全集成的平台,通过特征应变方法重建任意二维和三维几何形状的残余应力场,解决了这一空白。通过高级脚本完全在ANSYS®APDL环境中实现,它消除了外部依赖,同时确保了计算稳健性。其模块化设计和直观的图形界面简化了设置,最大限度地减少了用户干预,并增强了研究和工业应用的可访问性。该工具的能力通过涉及任意形状的大规模表面处理组件的案例研究得到验证,证明了其准确性、可扩展性和部署就绪性。EigenRec3D提供了集成到先进制造工作流程的途径,包括增材制造。
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引用次数: 0
Domain-embedded deep learning frameworks for topology optimization: Enhancing structural performance under data scarce environments 面向拓扑优化的领域嵌入式深度学习框架:增强数据稀缺环境下的结构性能
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-11-08 DOI: 10.1016/j.advengsoft.2025.104064
Geonwoo Lee , Mingyu Lee , Ikjin Lee
Recently, the rapid advancement of deep learning technology has led to the development of numerous topology optimization approaches, significantly reducing computational costs. However, conventional deep learning-based methods inherently suffer from a chronic limitation. They require large-scale data to extract features from the data itself. In particular, in the worst-case scenario where the data is insufficient, these methods may fail to capture the physical characteristics of the structure accurately, potentially leading to physically meaningless and unrealistic results. To solve this problem, this paper proposes an enhanced deep learning model suitable for topology optimization. The main novelty of this study is embedding the feature of topology optimization into a deep learning model. To effectively embed the topology domain, the proposed method introduces three key strategies. Firstly, topology convolutional neural network (CNN) filter layers are incorporated into the neural network model. A CNN is a specialized deep learning architecture designed for grid-structured data such as images, and the topology CNN filter layers are specifically designed to enhance structural connectivity by considering the influence of neighboring elements. Secondly, the pixel-based loss function is augmented with physics-informed loss functions that encapsulate the physical knowledge of topology optimization. Thirdly, a modified output layer is added to prevent zero values in the structure, thereby enhancing numerical stability. Numerical experiments demonstrate that the proposed deep learning approach successfully overcomes the limitations of conventional deep learning methods in data-scarce environments. Furthermore, the results confirm that the proposed method produces designs comparable to the traditional SIMP method.
近年来,深度学习技术的快速发展导致了许多拓扑优化方法的发展,大大降低了计算成本。然而,传统的基于深度学习的方法固有地受到长期限制。它们需要大规模的数据来从数据本身中提取特征。特别是,在数据不足的最坏情况下,这些方法可能无法准确捕获结构的物理特性,可能导致物理上毫无意义和不切实际的结果。为了解决这一问题,本文提出了一种适用于拓扑优化的增强型深度学习模型。本研究的主要新颖之处在于将拓扑优化的特征嵌入到深度学习模型中。为了有效地嵌入拓扑域,该方法引入了三个关键策略。首先,在神经网络模型中加入拓扑卷积神经网络(CNN)滤波层;CNN是一种专门为图像等网格结构数据设计的深度学习架构,拓扑CNN滤波器层是专门设计的,通过考虑相邻元素的影响来增强结构连通性。其次,将基于像素的损失函数扩展为包含拓扑优化物理知识的物理通知损失函数。第三,增加修正输出层,防止结构出现零值,提高数值稳定性。数值实验表明,所提出的深度学习方法成功地克服了传统深度学习方法在数据稀缺环境中的局限性。此外,结果证实了该方法产生的设计可与传统的SIMP方法相媲美。
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引用次数: 0
Rigid-flexible coupling dynamic modeling and adaptive intelligent composite control for a novel redundantly actuated flexible parallel robot 一种新型冗余驱动柔性并联机器人的刚柔耦合动力学建模与自适应智能复合控制
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-11-06 DOI: 10.1016/j.advengsoft.2025.104048
Dong Liang , Manjun Cui , Shiyou Li , Boyan Chang , Zhen Wang , Junpeng Zhang
Due to complex nonlinear closed-loop constraints and structural flexibility, the dynamic modeling and control issue on flexible parallel robots is much more challenging compared to serial counterparts. Oriented to the demand of the high-end manufacturing field, this paper proposes a novel lightweight redundant parallel robot with cross layout of guide rail. Based on assumed mode discretization and Kane’s formulation, a general rigid-flexible coupling dynamic model of arbitrary branch incorporating n-order modes is derived. Leveraging modular ideology, the complete rigid-flexible coupling dynamic model of the system is established combining with nonlinear constraint equations, which is solved by the Runge-Kutta algorithm, modal truncation and forward dynamics methodology. The dynamic response comparison results between the redundant parallel robot and the non-redundant parallel robot reveal that the redundant actuation can suppress the elastic vibration. The rigid-flexible coupling dynamic model is then validated by a physical simulation model developed through the MATLAB/Simscape® platform using the finite segment approach. The electromechanical coupling dynamic model is further formulated by integrating the rigid-flexible coupling dynamic model with the permanent magnet synchronous motor and smart material. An adaptive intelligent composite control strategy is proposed to achieve trajectory tracking and vibration suppression. The comparison results with the other three control strategies demonstrate that the adaptive intelligent composite control strategy has superior control performance, exhibiting potential application prospects.
由于复杂的非线性闭环约束和结构的灵活性,柔性并联机器人的动力学建模和控制问题比串行机器人更具挑战性。针对高端制造领域的需求,提出了一种新型导轨交叉布置的轻型冗余并联机器人。基于假设模态离散化和Kane公式,推导了包含n阶模态的任意分支刚柔耦合动力学一般模型。利用模块化思想,结合非线性约束方程,建立了系统的完整刚柔耦合动力学模型,采用龙格-库塔算法、模态截断和正演动力学方法进行求解。将冗余并联机器人与非冗余并联机器人的动态响应进行对比,结果表明冗余驱动可以抑制弹性振动。然后通过MATLAB/Simscape®平台使用有限段方法开发的物理仿真模型验证刚柔耦合动态模型。将刚柔耦合动力学模型与永磁同步电机和智能材料相结合,进一步建立机电耦合动力学模型。提出了一种自适应智能复合控制策略来实现轨迹跟踪和振动抑制。与其他三种控制策略的对比结果表明,自适应智能复合控制策略具有优越的控制性能,具有潜在的应用前景。
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引用次数: 0
A physics-informed machine learning computational framework for solving Mohr-Coulomb plasticity in geomechanics 一个物理信息的机器学习计算框架,用于求解地质力学中的莫尔-库仑塑性
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-11-06 DOI: 10.1016/j.advengsoft.2025.104061
Ran Yuan , Xi-Long Huang , Yong Fang , Kiyonobu Kasama , Yin Cheng , Yi He
This paper develops a Physics-Informed Neural Network (PINN) framework for solving Mohr-Coulomb (M-C) plasticity in geomechanics, and the plane strain layered perforated soils subjected to surface compression pressure are employed to validate the PINN solutions, through comparisons with parallel numerical experiments conducted in OptumG2. To incorporate the physical information for the elasto-plastic problem into neural networks (NNs), two modified multi-objective loss functions, respectively known as the collocation loss function and the Least Squares Weighted Residual (LSWR) loss function, are constructed through coarse data-driven information and physical constrains, consisting of M-C constitutive relations, associated/non-associated flow rules, Karush-Kuhn-Tucker (KKT) conditions, equilibrium conditions, and boundary conditions. The total loss function incorporates terms obtained from Finite Element Method (FEM) solutions for a range of elastoplastic field variables, i.e., stress and displacement, to inform the physical knowledge fitting. By employing several independently operating and densely connected artificial neural networks (ANNs), the PINN framework achieves the M-C plastic solutions by minimizing the designed total loss functions. Furthermore, influences of sample size, sampling strategy, and the loss function, on performances of the proposed PINN framework, are investigated for parametric analysis. In all cases, the PINN predictions were compared with finite element solutions at 145,023 mesh points, showing that over 90% of points had relative errors within 10%. The proposed PINN model is effective for data-scarce geotechnical problems, though its performance in regions with significant rates of change in physical quantity still requires further improvement.
本文建立了求解地质力学中moh - coulomb (M-C)塑性问题的物理信息神经网络(PINN)框架,并利用表面压缩压力作用下的平面应变分层穿孔土与OptumG2并行数值实验进行了对比,验证了PINN解的有效性。为了将弹塑性问题的物理信息整合到神经网络中,通过粗数据驱动的信息和物理约束,包括M-C本构关系、关联/非关联流动规则、Karush-Kuhn-Tucker (KKT)条件、平衡条件、约束条件和约束条件,构建了两个改进的多目标损失函数,分别称为搭配损失函数和最小二乘加权残差(LSWR)损失函数。还有边界条件。总损失函数结合了从有限元法(FEM)解中获得的一系列弹塑性场变量(即应力和位移)的项,以告知物理知识拟合。通过使用多个独立运行且紧密连接的人工神经网络(ann), PINN框架通过最小化设计的总损失函数来实现M-C塑性解决方案。此外,研究了样本大小、采样策略和损失函数对所提出的PINN框架性能的影响,以进行参数分析。在所有情况下,将PINN预测与145,023个网格点的有限元解进行比较,显示超过90%的点的相对误差在10%以内。提出的PINN模型对于数据稀缺的岩土工程问题是有效的,尽管其在物理量变化速率较大的地区的表现仍需进一步改进。
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引用次数: 0
Numerical boundary treatment in meshfree collocation for lid-driven cavity flow in stream function-vorticity form 流函数涡量型盖驱动腔流无网格配置的数值边界处理
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-11-04 DOI: 10.1016/j.advengsoft.2025.104062
Judy P. Yang, Yu-Hui Kao
A nonlinear collocation method incorporating numerical boundary treatment is developed to solve lid-driven cavity flow problems governed by the Navier-Stokes equations in the stream function-vorticity form. In contrast to approaches that rely solely on the vorticity formulation, the present method avoids the computational challenges associated with evaluating fourth-order derivatives of reproducing kernel shape functions. To address the difficulties posed by non-physical vorticity boundary conditions, a higher-order finite difference-based numerical boundary scheme is introduced, in which Neumann boundary conditions for the stream function are implicitly enforced. The effectiveness and accuracy of the method are validated through a series of benchmark investigations, demonstrating its robustness and capability to handle a wide range of Reynolds numbers in lid-driven cavity flow problems.
提出了一种结合数值边界处理的非线性配点法,用于求解流函数涡量形式的Navier-Stokes方程下的盖驱动腔体流动问题。与仅依赖涡量公式的方法相比,本方法避免了与评估再现核形状函数的四阶导数相关的计算挑战。为了解决非物理涡度边界条件带来的困难,引入了一种基于高阶有限差分的数值边界格式,其中隐式执行流函数的诺伊曼边界条件。通过一系列的基准研究,验证了该方法的有效性和准确性,证明了其鲁棒性和处理大范围雷诺数的能力。
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引用次数: 0
Optimal local truncation error method for 3-D elastodynamics interface problems on unfitted Cartesian meshes 非拟合笛卡尔网格三维弹性动力学界面问题的最优局部截断误差方法
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-11-01 DOI: 10.1016/j.advengsoft.2025.104049
A. Idesman, W. Ajwad, M. Mobin
This study expands the optimal local truncation error method (OLTEM) with unfitted Cartesian meshes, designed for 2-D elastodynamics with interfaces (wave propagation and structural dynamics), to the general 3-D case and non-homogeneous interface conditions. The technique employs compact 27-point stencils, similar to those used in linear finite elements, while avoiding the introduction of additional unknowns at material interfaces. Importantly, the global semi-discrete equations retain a similar structure for homogeneous and heterogeneous materials. OLTEM with the diagonal mass matrix, suitable for explicit time-integration schemes, represents a subset of the broader formulation using the non-diagonal mass matrix.
A significant innovation in this work is a new 3-D post-processing procedure for stress calculations. It improves accuracy by incorporating accelerations and the governing elastodynamics equations into the analysis. Like the primary computations, this post-processing technique utilizes compact 27-point stencils. The new post-processing procedure outperforms traditional methods that depend solely on displacements.
OLTEM with unfitted Cartesian meshes shows superior accuracy compared to linear finite elements with equivalent stencils and conformal meshes, while requiring significantly fewer degrees of freedom (DOF). For instance, at an accuracy of 0.1% for the displacements, OLTEM with the non-diagonal mass matrix reduces the number of DOF by more than 104 times; at an accuracy of 0.1% for the stresses, OLTEM with the new post-processing procedure reduces the number of DOF about 2×106 times compared to linear finite elements. OLTEM also provides increased computational efficiency compared to high-order finite elements, despite their wider stencils and conformal meshes.
本研究将非拟合笛卡尔网格的最优局部截断误差法(OLTEM)扩展到一般三维情况和非均匀界面条件下,该方法适用于具有界面(波传播和结构动力学)的二维弹性动力学。该技术采用紧凑的27点模板,类似于线性有限元中使用的模板,同时避免了在材料界面引入额外的未知元素。重要的是,对于均匀和非均匀材料,全局半离散方程保持了类似的结构。具有对角质量矩阵的OLTEM,适用于显式时间积分方案,代表了使用非对角质量矩阵的更广泛公式的子集。这项工作的一项重大创新是用于应力计算的新的三维后处理程序。通过将加速度和控制弹性动力学方程纳入分析,提高了精度。与初级计算一样,这种后处理技术使用紧凑的27点模板。新的后处理程序优于仅依赖位移的传统方法。与具有等效模板和保形网格的线性有限元相比,具有非拟合笛卡尔网格的OLTEM具有更高的精度,同时所需的自由度(DOF)显着降低。例如,在位移精度为0.1%的情况下,使用非对角质量矩阵的OLTEM将自由度数量减少了104倍以上;与线性有限元相比,具有新的后处理程序的OLTEM在0.1%的应力精度下减少了大约2×106次的自由度。尽管OLTEM具有更宽的模板和保形网格,但与高阶有限元相比,OLTEM还提供了更高的计算效率。
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引用次数: 0
An efficient multiscale coupling method for simulations of reactor-scale chemical vapor deposition with microstructural features 具有微结构特征的反应器级化学气相沉积多尺度耦合模拟方法
IF 5.7 2区 工程技术 Q2 COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS Pub Date : 2025-10-30 DOI: 10.1016/j.advengsoft.2025.104051
Taegeun Kim , Hyoungsoo Ko , Jaewon Jang , Sejin Kim , Sunyoung Park , Jae Myung Choe , Young-gu Kim , Dae Sin Kim , Sangseung Lee , Donghyun You
An efficient multiscale coupling method is proposed for simulations of reactor-scale chemical vapor deposition (CVD) with microstructural features. Reactor-scale and microstructure-resolved feature-scale models are coupled through an effective reaction rate formalism, enabling high-resolution deposition simulations while significantly reducing computational cost. A parameterized microstructural model is introduced, in which the relationship between the effective reaction rate and local species consumption rates in the reactor-scale model is directly mapped using precomputed Monte Carlo simulation data. This eliminates the need for iterative calculations or direct numerical simulations of the surface reaction across all the discretized grid points on the wafer, ensuring predictive accuracy while enhancing computational efficiency. Furthermore, an adaptive time-stepping method is developed, dynamically adjusting the time-step size for the feature-scale model based on variations in the effective reaction rate. Through this approach, simulation time is reduced by more than one-third compared to conventional fixed time-step methods, while preserving the accuracy of the effective reaction rate model. The proposed method enables practical and scalable multiscale CVD simulations applicable to industrial reactor design and process optimization, establishing a computationally efficient strategy for integrating reactor-scale and microstructure-resolved feature-scale models.
提出了一种高效的多尺度耦合方法来模拟具有微观结构特征的反应器尺度化学气相沉积过程。反应器尺度和微结构分辨率特征尺度模型通过有效的反应速率形式相结合,实现高分辨率沉积模拟,同时显著降低计算成本。引入参数化微结构模型,利用预先计算的蒙特卡罗模拟数据直接映射反应器尺度模型中有效反应速率与局部物质消耗率之间的关系。这消除了对晶圆上所有离散网格点的表面反应进行迭代计算或直接数值模拟的需要,确保了预测的准确性,同时提高了计算效率。在此基础上,提出了一种基于有效反应速率变化动态调整特征尺度模型时间步长的自适应时间步长方法。通过该方法,与传统的固定时间步长方法相比,模拟时间减少了三分之一以上,同时保持了有效反应速率模型的准确性。该方法实现了适用于工业反应器设计和工艺优化的实用和可扩展的多尺度CVD模拟,为集成反应器尺度和微观结构分辨率特征尺度模型建立了一种计算效率高的策略。
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Advances in Engineering Software
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