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2 I3A,
3 LTDS,
Group, France
Diego.Canales-Aguilera@ec-nantes.fr, b Adrien.Leygue@ec-nantes.fr,
c
Francisco.Chinesta@ec-nantes.fr, d ecueto@unizar.es, e Eric.Feulvarch@enise.fr,
f
Jean-Michel.Bergheau@enise.fr, g Yannick.Vincent@esi-group.com,
h
Frederic.Boitout@esi-group.com
Keywords: PGD, updated-Lagrangian, Forming processes.
Abstract. A new efficient udated-Lagrangian strategy for numerical simulations of material forming
processes is presented in this work. The basic ingredients are the in-plane-out-of-plane PGD-based
decomposition and the use of a robust numerical integration technique (the Stabilized Conforming
Nodal Integration). This strategy is of general purpose, although it is especially well suited for plateshape geometries. This paper is devoted to show the feasibility of the technique through some simple
numerical examples.
Introduction
The numerical simulation of material forming processes is a fundamental tool in the industry. It allows
reducing the design cycle time and optimizing the process without the need for costly and time consuming test campaigns. However, it is a very challenging task, even for the high performance computation
available nowadays. The simulation of processes such as co-extrusion, friction stir welding (FSW) or
resin transfer moulding (RTM) involves some inherent difficulties: thermomechanical coupled formulations, large deformations or the need for computing the thermomechanical path of the material
particles to compute important quantities of interest (such as residual stresses or the microstructure).
Despite the fact that accurate simulations tools are available, the actual industry demands more
efficient solutions to improve its competitiveness. With this aim, efforts have been made to apply
different reduced order modeling methods to these simulations. Among others, we can highlight the
contributions of the Proper Generalized Decomposition in this field [REF libro procesos].
Proposed strategy
The proposed strategy can be seen as the natural extension of the in-plane-out-of-plane based on the
Proper Generalized Decomposition (PGD) for an updated-Lagrangian framework. This technique,
developed by B.Bognet et al [REF], has been used in Eulerian frameworks to simulate solids an nonNewtonian fluids [REF] with impressive saving of computational cost compared with traditional FE
methods.
The main idea of our approach is to take advantage of updated-Lagrangian methods, very convenient for material forming simulations, but with a significant reduction of its computational complexity
using the in-plane-out-of-plane PGD-based decomposition. The material particles positions and the
physical values are projected into a plane and into an axis. Using these nodal projections two functional spaces are constructed, 2D and 1D respectively. Then, the thermomechanical problem is solved
as a succession of problems 2D and 1D in these spaces thanks to the in-plane-out-of-plane PGD-based
formulation. In the 2D space the projected mesh could be, eventually, very distorted. For a better performance of the PGD, the Stabilized Conforming Nodal Integration (SCNI) is introduced to compute
the 2D PGD operators. Once the solution is obtained, the primary variables can be reconstructed in the
material particles of the 3D domain and update their positions. This reconstruction does not involve
any interpolation or projection stage, avoiding the numerical diffusion and other numerical difficulties. After the updating step, these steps are repeated until the end of the simulation. In the Fig. 1, a
general scheme of the strategy is shown.
(2)
(3)
where , the fraction of mechanical energy transformed to heat and d the strain rate tensor. Together
with these equations, a behavior law and the appropriate boundary conditions should be considered.
The mechanical and thermal problem will be solved iteratively.
Considering a plate-shape domain = I, this technique assumes the next separated approximation of the velocity field
N
uxy (x, y) uiz (z)
u(x, y, z)
i
vxy
(x, y) vzi (z) ,
v(x, y, z) = v(x, y, z)
(4)
i
i=1
w(x, y, z)
wxy (x, y) wzi (z)
where uxy (x, y), vxy (x, y) and wxy (x, y) are function of the in-plane coordinates whereas uz (z), vzi (z)
and wz (z) are functions involving the thickness coordinate. Similarly, the strain rate tensor can be
expressed in separated way. For intensive variables, such as the viscosity, an SVD decomposition
should be perform in order to obtained its in-plane-out-of-plane separation:
(x, y, z) =
z
xy
k (x, y)k (z).
(5)
k=1
(6)
(7)
n1
with K and n two rheological parameters. The equivalent strain rate d given by:
d = 2(d : d)
(8)
(9)
(10)
The Stabilized Conforming Nodal Integration. In the proposed strategy, after updating the nodal
position, their orthogonal projections into a plane and an axis constitute the nodal position of the
interpolant spaces used for the PGD solution. One problem we have face is that the 2D mesh will be,
eventually, very distorted and the numerical integration of the discrete operators may be not accurate
enough.
Chen et al. [?] introduced the SCNI technique to perform an accurate nodal integration in meshless
methods. However, it is very interesting that SCNI can be incorporated into traditional FE interpolants
to produce a very robust method to deal with distorted mesh.
The SCNI is based on the assumed strain method, in which a modified gradient is introduced at
the integration point (node):
v(x) d,
(11)
v(xi ) =
Ai
i
where xi are the coordinates of node ni . The cell i is one element of any partition of the domain.
Typically a Voronoi tessellation is used.
i) = 1
d(x
Ai
1
d(x)d =
Ai
1
2
u
x
u
y
(
1 u
2
v
x
)
w
x
1
2
1
2
(
(
u
y
v
x
v
y
v
z
w
y
)
)
u(x)nx
(u(x)ny + v(x)nx )
2
1
1
(u(x)ny + v(x)nx )
v(x)ny
d(xi ) =
2
Ai
1
1
(u(x)n
+
w(x)n
)
(v(x)n
z
x
z + w(x)ny )
i
2
2
( u
+
( z
1 v
+
2 z
1
2
w
z
)
)
w
d.
y
w
x
(12)
+ w(x)nx )
+ w(x)ny ) d.
w(x)nz
(13)
After the discretization, the derivates of the shape functions are computed through the value of the
shape functions itself in certain integration points. These integration points are distributed along the
boundaries of the elements of the partition.
1
(u(x)nz
2
1
(v(x)nz
2
0.5
0.4
0.3
0.2
0.1
0.
106
105
104
103
102
Viscosity ratio 1 /2
101
.
100
proved the feasibility of the numerical algorithm: we can solve a 3D flow model in an updatedLagrangian framework with a computational cost in the order of several 2D problems. Moreover,
the thermomechanical history of the material particles is computed directly from the simulation. For
instance, we can study the evolution of the viscosity of a particle during the process. In the Fig. 5,
we can observe how the viscosity of the particle decrease of the when it passes through the area of
the tool, where the strain ratios are high due to the rotation of the pin. A picture of this simulation is
presented in the Fig. 6, where the system of reference is attached to the pin axis.
[3] Y. Mishing, in: Diffusion Processes in Advanced Technological Materials, edtied by D. Gupta
Noyes Publications/William Andrew Publising, CityplaceNorwich, StateNY (2004), in press.
[4] G. Henkelman, G.Johannesson and H. Jnsson, in: Theoretical Methods in Condencsed Phase
Chemistry, edited by S.D. Schwartz, volume 5 of Progress in Theoretical Chemistry and Physics,
chapter, 10, Kluwer Academic Publishers (2000).