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The main purpose of this paper is to present a comprehensive upscale theory of the thermo-mechanical coupling particle simulation for three-dimensional (3D) large-scale non-isothermal problems, so that a small 3D length-scale particle model can exactly reproduce the same mechanical and thermal results with that of a large 3D length-scale one.

The objective is achieved by following the scaling methodology proposed by Feng and Owen (2014).

After four basic physical quantities and their similarity-ratios are chosen, the derived quantities and its similarity-ratios can be derived from its dimensions. As the proposed comprehensive 3D upscale theory contains five similarity criteria, it reveals the intrinsic relationship between the particle-simulation solution obtained from a small 3D length-scale (e.g. a laboratory length-scale) model and that obtained from a large 3D length-scale (e.g. a geological length-scale) one. The scale invariance of the 3D interaction law in the thermo-mechanical coupled particle model is examined. The proposed 3D upscale theory is tested through two typical examples. Finally, a practical application example of 3D transient heat flow in a solid with constant heat flux is given to illustrate the performance of the proposed 3D upscale theory in the thermo-mechanical coupling particle simulation of 3D large-scale non-isothermal problems. Both the benchmark tests and application example are provided to demonstrate the correctness and usefulness of the proposed 3D upscale theory for simulating 3D non-isothermal problems using the particle simulation method.

The paper provides some important theoretical guidance to modeling 3D large-scale non-isothermal problems at both the engineering length-scale (i.e. the meter-scale) and the geological length-scale (i.e. the kilometer-scale) using the particle simulation method directly.

This paper aims to develop a hybrid finite difference‐finite element method and apply it to solve the three‐dimensional energy equation in non‐isothermal fluid flow past over a tube.

To implement the hybrid scheme, the tube length is partitioned into uniform segments by choosing grid points along its length, and a plane perpendicular to the tube axis is drawn at each of the points. Subsequently, the Taylor‐Galerkin finite element technique is employed to discretize the energy equation in the planes; while the derivatives along the tube are discretized using the finite difference method.

To demonstrate the validity of the proposed numerical scheme, three‐dimensional test cases have been solved using the method. The variation of L²‐norm of the error with mesh refinement shows that the numerical solution converges to the exact solution with mesh refinement. Moreover, comparison of the computational time duration shows that the proposed method is approximately three times faster than the 3D finite element method. In the non‐isothermal fluid flow around a tube for Re=250 and Pr=0.7, the results show that the Nusselt number decreases with the increase in the tube length and, for the tube length greater than six times the tube diameter, the average Nusselt number converges to the value for the two‐dimensional case.

A hybrid finite difference‐finite element method has been developed and applied to solve the 3D transient energy equation for different test cases. The proposed method is faster, and computationally more efficient, compared with the 3D finite element method.

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.

The purpose of this paper is to present an upscale theory of the thermal-mechanical coupling particle simulation for non-isothermal problems in two-dimensional quasi-static system, under which a small length-scale particle model can exactly reproduce the same mechanical and thermal results with that of a large length-scale one.

The objective is achieved by extending the upscale theory of particle simulation for two-dimensional quasi-static problems from an isothermal system to a non-isothermal one.

Five similarity criteria, namely geometric, material (mechanical and thermal) properties, gravity acceleration, (mechanical and thermal) time steps, thermal initial and boundary conditions (Dirichlet/Neumann boundary conditions), under which a small-length-scale particle model can exactly reproduce both the mechanical and thermal behavior with that of a large length-scale model for non-isothermal problems in a two-dimensional quasi-static system are proposed. Furthermore, to test the proposed upscale theory, two typical examples subjected to different thermal boundary conditions are simulated using two particle models of different length scale.

The paper provides some important theoretical guidances to modeling thermal-mechanical coupled problems at both the engineering length scale (i.e. the meter scale) and the geological length scale (i.e. the kilometer scale) using the particle simulation method directly. The related simulation results from two typical examples of significantly different length scales (i.e. a meter scale and a kilometer scale) have demonstrated the usefulness and correctness of the proposed upscale theory for simulating non-isothermal problems in two-dimensional quasi-static system.

This paper sets out to show the feasibility of the genetic algorithm inverse method for the determination of the parameters of crystallization kinetics laws in isothermal and non‐isothermal conditions, using multiple experiments.

The mathematical model for crystallization kinetics determination and the numerical methods of its resolution are introduced. Crystallization kinetic parameters determined by approximate physical analysis and the inverse genetic algorithm method are presented. Injection molding simulations taking into account crystallization are performed using the finite element method.

It is necessary to perform the optimization on two parameters, transformed volume fraction and number of spherulites to obtain correct results. It is possible to use results from different samples, in spite of the dispersion of some values.

Experimental data for isothermal and non‐isothermal conditions were used and obtained good results for the parameters of crystallization kinetics laws from which the evolutions of overall crystallization kinetics and crystalline microstructure were deduced. Nevertheless, the dispersion of the experimental data concerning the number of spherulites obtained with different samples is important. The evolution of the number of spherulites is required for the optimization to get correct results.

An important result of this work is that the genetic algorithm optimization can be applied to this problem where the experiments cannot be performed with a single sample and the experimental data for the number of spherulites have low precision. Even if only the crystallization kinetics was considered, the feasibility in molding simulation has been shown.

Simulation of crystallization in injection molding is very important for a later prediction of the end‐use properties.

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for the last five years, and more than 1100 references are listed.

This paper aims to develop experimentally validated numerical models to accurately characterize the cross-sectional geometry of the deposited beads in a fused filament fabrication (FFF) process under various process conditions.

The presented numerical model is investigated under various fidelity with varying computational complexity. To this end, comparisons between the Newtonian, non-newtonian, isothermal and non-isothermal computational models are presented for the extrusion of polylactic acid material in an FFF process. The computational model is validated through an experimental study on an off-the-shelf FFF printer. Microscope images of experimentally printed FFF bead cross-sections corresponding to various printing conditions are digitally processed for the validation. In the experimental study, common practical printing conditions for an FFF process are tested, and the results are compared to the numerical model.

Microscope image analyses of the cross-sectional geometries of deposited beads show that the numerical model provides a precise characterization of the cross-sectional geometry under varying process parameters in terms of the cross-section outline, bead height and width. The results show that the nozzle-to-table distance has a great effect on the bead shape when compared to the extrusion rate at a given nozzle-to-table distance. Comparison of the various computational models show that the non-Newtonian isothermal model provides the best tradeoff between computational complexity and model accuracy.

The authors provide detailed computational models, including the extruder nozzle geometry for cases ranging from Newtonian isothermal models to non-Newtonian non-isothermal models with experimental validation. The validation study is conducted for practical process parameters that are commonly used in FFF in practice and show that the computational models provide an accurate depiction of the true process outputs. As the developed models can accurately predict process outputs, they can be used in further applications for process planning and parameter tuning.

To provide a selective bibliography for researchers working with bulk material forming (specifically the forging, rolling, extrusion and drawing processes) with sources which can help them to be up‐to‐date.

A range of published (1996‐2005) works, which aims to provide theoretical as well as practical information on the material processing namely bulk material forming. Bulk deformation processes used in practice change the shape of the workpiece by plastic deformations under forces applied by tools and dies.

Provides information about each source, indicating what can be found there. Listed references contain journal papers, conference proceedings and theses/dissertations on the subject.

It is an exhaustive list of papers (1,693 references are listed) but some papers may be omitted. The emphasis is to present papers written in English language. Sheet material forming processes are not included.

A very useful source of information for theoretical and practical researchers in computational material forming as well as in academia or for those who have recently obtained a position in this field.

There are not many bibliographies published in this field of engineering. This paper offers help to experts and individuals interested in computational analyses and simulations of material forming processes.

This paper aims to develop a numerical model of bead spreading architecture of a viscous polymer in fused filament fabrication (FFF) process with different nozzle geometry. This paper also focuses on the manufacturing feasibility of the nozzles and 3D printing of the molten beads using the developed nozzles.

The flow of a highly viscous polymer from a nozzle, the melt expansion in free space and the deposition of the melt on a moving platform are captured using the FLUENT volume of fluid (VOF) method based computational fluid dynamics code. The free surface motion of the material is captured in VOF, which is governed by the hydrodynamics of the two-phase flow. The phases involved in the numerical model are liquid polymer and air. A laminar, non-Newtonian and non-isothermal flow is assumed. Under such assumptions, the spreading characteristic of the polymer is simulated with different nozzle-exit geometries. The governing equations are solved on a regular stationary grid following a transient algorithm, where the boundary between the polymer and the air is tracked by piecewise linear interface construction (PLIC) to reconstruct the free surface. The prototype nozzles were also manufactured, and the deposition of the molten beads on a flatbed was performed using a commercial 3D printer. The deposited bead cross-sections were examined through optical microscopic examination, and the cross-sectional profiles were compared with those obtained in the numerical simulations.

The numerical model successfully predicted the spreading characteristics and the cross-sectional shape of the extruded bead. The cross-sectional shape of the bead varied from elliptical (with circular nozzle) to trapezoidal (with square and star nozzles) where the top and bottom surfaces are significantly flattened (which is desirable to reduce the void spaces in the cross-section). The numerical model yielded a good approximation of the bead cross-section, capturing most of the geometric features of the bead with a reasonable qualitative agreement compared to the experiment. The quantitative comparison of the cross-sectional profiles against experimental observation also indicated a favorable agreement. The significant improvement observed in the bead cross-section with the square and star nozzles is the flattening of the surfaces.

The developed numerical algorithm attempts to address the fundamental challenge of voids and bonding in the FFF process. It presents a new approach to increase the inter-bead bonding and reduce the inter-bead voids in 3D printing of polymers by modifying the bead cross-sectional shape through the modification of nozzle exit-geometry. The change in bead cross-sectional shape from elliptical (circular) to trapezoidal (square and star) cross-section is supposed to increase the contact surface area and inter-bead bonding while in contact with adjacent beads.