Modelling convection in solidification processes using stabilized finite element techniques

Solidification of dendritic alloys is modelled using stabilized finite element techniques to study convection and macrosegregation driven by buoyancy and shrinkage. The adopted governing macroscopic conservation equations of momentum, energy and species transport are derived from their microscopic counterparts using the volume‐averaging method. A single domain model is considered with a fixed numerical grid and without boundary conditions applied explicitly on the freezing front. The mushy zone is modelled here as a porous medium with either an isotropic or an anisotropic permeability. The stabilized finite‐element scheme, previously developed by authors for modelling flows with phase change, is extended here to include effects of shrinkage, density changes and anisotropic permeability during solidification. The fluid flow scheme developed includes streamline‐upwind/Petrov–Galerkin (SUPG), pressure stabilizing/Petrov–Galerkin, Darcy stabilizing/Petrov–Galerkin and other stabilizing terms arising from changes in density in the mushy zone. For the energy and species equations a classical SUPG‐based finite element method is employed with minor modifications. The developed algorithms are first tested for a reference problem involving solidification of lead–tin alloy where the mushy zone is characterized by an isotropic permeability. Convergence studies are performed to validate the simulation results. Solidification of the same alloy in the absence of shrinkage is studied to observe differences in macrosegregation. Vertical solidification of a lead–tin alloy, where the mushy zone is characterized by an anisotropic permeability, is then simulated. The main aim here is to study convection and demonstrate formation of freckles and channels due to macrosegregation. The ability of stabilized finite element methods to model a wide variety of solidification problems with varying underlying phenomena in two and three dimensions is demonstrated through these examples. Copyright © 2005 John Wiley & Sons, Ltd.     

An object oriented implementation of a front tracking finite element method for directional solidification processes

This paper focuses on the numerical simulation of phase‐change processes using a moving finite element technique. In particular, directional solidification and melting processes for pure materials and binary alloys are studied. The melt is modelled as a Boussinesq fluid and the transient Navier–Stokes equations are solved simultaneously with the transient heat and mass transport equations as well as the Stefan condition. The various streamline‐upwind/Petrov–Galerkin‐based FEM simulators developed for the heat, flow and mass transport subproblems are reviewed. The use of classes, virtual functions and smart pointers to represent and link the particular simulators in order to model a phase change process is discussed. The freezing front is modelled using a spline interpolation, while the mesh motion is defined from the freezing front motion using a transfinite mapping technique. Various two‐ and three‐dimensional numerical tests are analysed and discussed to demonstrate the efficiency of the proposed techniques. Copyright © 1999 John Wiley & Sons, Ltd.     

Homogenized free surface flow in porous media for wet‐out processing

This paper presents a novel porous media model for homogenized free surface flow, representing wet‐out composites processing. The model is derived from concepts of homogenization applied to a compressible two‐phase flow, accounting for capillary effects and the concept of relative permeability. Based on mass balance considerations, we obtain a nonlinear set of equations of convection‐diffusion type involving the mixture (fluid) pressure and the degree of saturation as primary fields. A staggered Galerkin finite element approach is employed to decouple the solution. Moreover, the streamline upwind/Petrov‐Galerkin technique is applied to attenuate the oscillations in the saturation solutions. The model accuracy and convergence of the finite element solutions are demonstrated through 1‐dimensional and 2‐dimensional examples, representing resin transfer molding flow processes.     

Two‐dimensional finite element method solution of a class of integro‐differential equations: Application to non‐Fickian transport in disordered media

A finite element method is developed to solve a class of integro‐differential equations and demonstrated for the important specific problem of non‐Fickian contaminant transport in disordered porous media. This transient transport equation, derived from a continuous time random walk approach, includes a memory function. An integral element is the incorporation of the well‐known sum‐of‐exponential approximation of the kernel function, which allows a simple recurrence relation rather than storage of the entire history. A two‐dimensional linear element is implemented, including a streamline upwind Petrov–Galerkin weighting scheme. The developed solver is compared with an analytical solution in the Laplace domain, transformed numerically to the time domain, followed by a concise convergence assessment. The analysis shows the power and potential of the method developed here. Copyright © 2017 John Wiley & Sons, Ltd.     

Finite element simulation of thin liquid film flow and heat transfer including a hydraulic jump

A numerical simulation has been performed to investigate planar and radial flows of thin liquid film subject to constant wall temperature or constant wall heat flux, considering the surface tension effect. To simulate the variation of the film height including a hydraulic jump, an Arbitrary Lagrangian–Eulerian (ALE) method is adopted in describing the governing equations. An iterative split algorithm is used to improve the continuity constraint in time marching of the governing equations which are discretized by Streamline Upwind Petrov–Galerkin (SUPG) finite element method. It has been shown clearly that the surface tension has to be considered in order to describe realistically a hydraulic jump preceded by a capillary ripple. The variation of the film height is in good agreement with the existing experimental data. Physical aspects of how the flowrate as well as temperature‐dependent fluid properties affect the formation of the hydraulic jump and the variation of the Nusselt number are discussed rationally. Copyright © 1999 John Wiley & Sons, Ltd.     

A least-squares front-tracking finite element method analysis of phase change with natural convection

This paper focuses on the numerical modelling of phase-change processes with natural convection. In particular, two-dimensional solidification and melting problems are studied for pure metals using an energy preserving deforming finite element model. The transient Navier–Stokes equations for incompressible fluid flow are solved simultaneously with the transient heat flow equations and the Stefan condition. A least-squares variational finite element method formulation is implemented for both the heat flow and fluid flow equations. The Boussinesq approximation is used to generate the bulk fluid motion in the melt. The mesh motion and mesh generation schemes are performed dynamically using a transfinite mapping. The consistent penalty method is used for modelling incompressibility. The effect of natural convection on the solid/liquid interface motion, the solidification rate and the temperature gradients is found to be important. The proposed method does not possess some of the false diffusion problems associated with the standard Galerkin formulations and it is shown to produce accurate numerical solutions for convection dominated phase-change problems.     

On stable equal-order finite element formulations for incompressible flow problems

In this work we discuss stable equal-order finite element formulations for incompressible flow problems based on Petrov–Galerkin methods, constructed by adding to the classical Galerkin formulation least-squares of the governing equations. Continuous and discontinuous pressure interpolations are considered. Numerical results are presented reinforcing the numerical analysis.     

A stable and adaptive semi-Lagrangian potential model for unsteady and nonlinear ship-wave interactions

We present an innovative numerical discretization of the equations of inviscid potential flow for the simulation of three-dimensional, unsteady, and nonlinear water waves generated by a ship hull advancing in water.The equations of motion are written in a semi-Lagrangian framework, and the resulting integro-differential equations are discretized in space via an adaptive iso-parametric collocation boundary element method, and in time via implicit backward differentiation formulas (BDF) with adaptive step size and variable order.When the velocity of the advancing ship hull is non-negligible, the semi-Lagrangian formulation (also known as Arbitrary Lagrangian Eulerian formulation or ALE) of the free-surface equations contains dominant transport terms which are stabilized with a streamwise upwind Petrov–Galerkin (SUPG) method.The SUPG stabilization allows automatic and robust adaptation of the spatial discretization with unstructured quadrilateral grids. Preliminary results are presented where we compare our numerical model with experimental results on a Wigley hull advancing in calm water with fixed sink and trim.     

Development of physically based meshes for two‐dimensional models of meandering channel flow

The choice of mesh generation and numerical solution strategies for two‐dimensional finite element models of fluvial flow have previously been based chiefly on experience and rule of thumb. This paper develops a rationale for the finite element modelling of flow in river channels, based on a study of flow around an annular reach. Analytical solutions of the two‐dimensional Shallow Water (St. Venant) equations are developed in plane polar co‐ordinates, and a comparison with results obtained from the TELEMAC‐2‐D finite element model indicates that of the two numerical schemes for the advection terms tested, a flux conservative transport scheme gives better results than a streamline upwind Petrov–Galerkin technique. In terms of mesh discretization, the element angular deviation is found to be the most significant control on the accuracy of the finite element solutions. A structured channel mesh generator is therefore developed which takes local channel curvature into account in the meshing process. Results indicate that simulations using curvature‐dependent meshes offer similar levels of accuracy to finer meshes made up of elements of uniform length, with the added advantage of improved model mass conservation in regions of high channel curvature. Copyright © 2000 John Wiley & Sons, Ltd.     

A control volume capacitance method for solidification modelling with mass transport

Capacitance methods are popular methods used for solidification modelling. Unfortunately, they suffer from a major drawback in that energy is not correctly transported through elements and so provides a source of inaccuracy. This paper is concerned with the development and application of a control volume capacitance method (CVCM) to problems where mass transport and solidification are combined. The approach adopted is founded on theory that describes energy transfer through a control volume (CV) moving relative to the transporting mass. An equivalent governing partial differential equation is established, which is designed to be transformable into a finite element system that is commonly used to model transient heat‐conduction problems. This approach circumvents the need to use the methods of Bubnov–Galerkin and Petrov–Galerkin and thus eliminates many of the stability problems associated with these approaches. An integration scheme is described that accurately caters for enthalpy fluxes generated by mass transport. Shrinkage effects are neglected in this paper as all the problems considered involve magnitudes of velocity that make this assumption reasonable. The CV approach is tested against known analytical solutions and is shown to be accurate, stable and computationally competitive. Copyright © 2002 John Wiley & Sons, Ltd.     

Thermo‐elasto‐plastic finite element analysis of quasi‐state processes in Eulerian reference frames

An Eulerian finite element formulation for quasi‐state one way coupled thermo‐elasto‐plastic systems is presented. The formulation is suitable for modeling material processes such as welding and laser surfacing. In an Eulerian frame, the solution field of a quasi‐state process becomes steady state for the heat transfer problem and static for the stress problem. A mixed small deformation displacement elasto‐plastic formulation is proposed. The formulation accounts for temperature dependent material properties and exhibits a robust convergence. Streamline upwind Petrov–Galerkin (SUPG) is used to remove spurious oscillations. Smoothing functions are introduced to relax the non‐differentiable evolution equations and allow for the use of gradient (stiffness) solution scheme via the Newton–Raphson method. A 3‐dimensional simulation of a laser surfacing process is presented to exemplify the formulation. Results from the Eulerian formulation are in good agreement with results from the conventional Lagrangian formulation. However, the Eulerian formulation is approximately 15 times faster than the Lagrangian. Copyright © 2001 John Wiley & Sons, Ltd.     

Petrov–Galerkin finite element methods with a hinged test space for singularly perturbed problems

In this paper we introduce finite element methods of Petrov–Galerkin type for the approximate solution of two-point boundary-value problems for singularly perturbed, second-order, ordinary, linear differential equations. We write down Petrov–Galerkin methods on a uniform mesh which have asymptotic error estimates, as the mesh size tends to zero, whose magnitude is independent of the singular perturbation parameter. This is in marked contrast to standard finite element methods which do not possess such a property on a uniform mesh. For these, typically, the error on a fixed uniform mesh blows up as the singular perturbation parameter tends to zero. This robust behaviour of these Petrov–Galerkin methods for singularly perturbed problems is achieved by choosing trial spaces of standard piecewise polynomial type, while the test spaces consist of hinged piecewise polynomials. We consider self-adjoint and non-self-adjoint two-point boundary-value problems with Dirichlet boundary conditions. We define hinged test spaces for both types of problem. We then introduce a number of sample problems and we present numerical solutions of these sample problems using a Petrov–Galerkin method with the appropriate hinged test space.     

Eulerian elasto‐visco‐plastic formulations for residual stress prediction

A stabilized, Galerkin finite element formulation for modeling the elasto‐visco‐plastic response of quasi‐steady‐state processes, such as welding, laser surfacing, rolling and extrusion, is presented in an Eulerian frame. The mixed formulation consists of four field variables, such as velocity, stress, deformation gradient and internal variable, which is used to describe the evolution of the material's resistance to plastic flow. The streamline upwind Petrov–Galerkin method is used to eliminate spurious oscillations, which may be caused by the convection‐type of stress, deformation gradient and internal variable evolution equations. A progressive solution strategy is introduced to improve the convergence of the Newton–Raphson solution procedure. Two two‐dimensional numerical examples are implemented to verify the accuracy of the Eulerian formulation. Copyright © 2008 John Wiley & Sons, Ltd.     

Analysis of flow in the spiral casing using a streamline upwind Petrov Galerkin method

Numerical simulation of complex three‐dimensional flow through the spiral casing has been accomplished using a finite element method. An explicit Eulerian velocity correction scheme has been deployed to solve the Reynolds average Navier–Stokes equations. The simulation has been performed to describe the flow in high Reynolds number (10⁶) regime. For spatial discretization, a streamline upwind Petrov Galerkin technique has been used. The velocity field and the pressure distribution inside the spiral casing corroborate the results available in literature. The flow structure reveals the fact that very strong secondary flow is evolved on the cross‐stream planes. Copyright © 1999 John Wiley & Sons, Ltd.     

Conservation properties of a time FE method. Part I: time‐stepping schemes for N‐body problems

In the present paper one‐step implicit integration algorithms for the N‐body problem are developed. The time‐stepping schemes are based on a Petrov–Galerkin finite element method applied to the Hamiltonian formulation of the N‐body problem. The approach furnishes algorithmic energy conservation in a natural way. The proposed time finite element method facilitates a systematic implementation of a family of time‐stepping schemes. A particular algorithm is specified by the associated quadrature rule employed for the evaluation of time integrals. The influence of various standard as well as non‐standard quadrature formulas on algorithmic energy conservation and conservation of angular momentum is examined in detail for linear and quadratic time elements. Copyright © 2000 John Wiley & Sons, Ltd.     

A variational multiscale method for particle-cloud tracking in turbomachinery flows

We present a computational method for simulation of particle-laden flows in turbomachinery. The method is based on a stabilized finite element fluid mechanics formulation and a finite element particle-cloud tracking method. We focus on induced-draft fans used in process industries to extract exhaust gases in the form of a two-phase fluid with a dispersed solid phase. The particle-laden flow causes material wear on the fan blades, degrading their aerodynamic performance, and therefore accurate simulation of the flow would be essential in reliable computational turbomachinery analysis and design. The turbulent-flow nature of the problem is dealt with a Reynolds-Averaged Navier–Stokes model and Streamline-Upwind/Petrov–Galerkin/Pressure-Stabilizing/Petrov–Galerkin stabilization, the particle-cloud trajectories are calculated based on the flow field and closure models for the turbulence–particle interaction, and one-way dependence is assumed between the flow field and particle dynamics. We propose a closure model utilizing the scale separation feature of the variational multiscale method, and compare that to the closure utilizing the eddy viscosity model. We present computations for axial- and centrifugal-fan configurations, and compare the computed data to those obtained from experiments, analytical approaches, and other computational methods.     

Time finite element methods for structural dynamics

Time finite element methods are developed for the equations of structural dynamics. The approach employs the time-discontinuous Galerkin method and incorporates stabilizing terms having least-squares form. These enable a general convergence theorem to be proved in a norm stronger than the energy norm. Results are presented from finite difference analyses of the time-discontinuous Galerkin and least-squares methods with various temporal interpolations and commonly used finite difference methods for structural dynamics. These results show that, for particular interpolations, the time finite element method exhibits improved accuracy and stability.     

A two‐scale approach for fluid flow in fractured porous media

A two‐scale numerical model is developed for fluid flow in fractured, deforming porous media. At the microscale the flow in the cavity of a fracture is modelled as a viscous fluid. From the micromechanics of the flow in the cavity, coupling equations are derived for the momentum and the mass couplings to the equations for a fluid‐saturated porous medium, which are assumed to hold on the macroscopic scale. The finite element equations are derived for this two‐scale approach and integrated over time. By exploiting the partition‐of‐unity property of the finite element shape functions, the position and direction of the fractures is independent from the underlying discretization. The resulting discrete equations are non‐linear due to the non‐linearity of the coupling terms. A consistent linearization is given for use within a Newton–Raphson iterative procedure. Finally, examples are given to show the versatility and the efficiency of the approach, and show that faults in a deforming porous medium can have a significant effect on the local as well as on the overall flow and deformation patterns. Copyright © 2006 John Wiley & Sons, Ltd.     

Stabilized finite element methods for vertically averaged multiphase flow for carbon sequestration

A computationally efficient numerical model that describes carbon sequestration in deep saline aquifers is presented. The model is based on the multiphase flow and vertically averaged mass balance equations, requiring the solution of two partial differential equations – a pressure equation and a saturation equation. The saturation equation is a nonlinear advective equation for which the application of Galerkin finite element method (FEM) can lead to non‐physical oscillations in the solution. In this article, we extend three stabilized FEM formulations, which were developed for uncoupled systems, to the governing nonlinear coupled PDEs. The methods developed are based on the streamline upwind, the streamline upwind/Petrov–Galerkin and the least squares FEM. Two sequential solution schemes are developed: a single step and a predictor–corrector. The range of Courant numbers yielding smooth and oscillation‐free solutions is investigated for each method. The useful range of Courant numbers found depends upon both the sequential scheme (single step vs predictor–corrector) and also the time integration method used (forward Euler, backward Euler or Crank–Nicolson). For complex problems such as when two plumes meet, only the SU stabilization with an amplified stabilization parameter gives satisfactory results when large time steps are used. Copyright © 2016 John Wiley & Sons, Ltd.     

Efficient finite element formulation for geothermal heating systems. Part II: transient

This paper presents an extension to the work presented in Part I of this series of two articles to the transient case. Emphasis is placed on the development of a new model for heat flow in a double U‐shape vertical borehole heat exchanger and its thermodynamic interactions with surrounding soil mass. The discretization of the spatial‐temporal domain of the heat pipe model is done by the use of the space–time finite element technique in conjunction with the Petrov–Galerkin method and the finite difference method. The paper shows that the proposed model and the choice of the discretization technique, in addition to the utilization of a sequential numerical algorithm for solving the resulting system of non‐linear equations, have contributed in reducing significantly the required number of finite elements necessary for describing geothermal heating systems. Details of the mathematical derivations and comparison to experimental data are presented. Copyright © 2006 John Wiley & Sons, Ltd.