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Aerospace assembly demands high drilling position accuracy for fastener holes. Hole position error correction is a key issue to meet the required hole position accuracy. This paper aims to propose a combined hole position error correction method to achieve high positioning accuracy.

The bilinear interpolation surface function based on the shape of the aerospace structure is capable of dealing with position error of non-gravity deformation. A gravity deformation model is developed based on mechanics theory to efficiently correct deformation error caused by gravity. Moreover, three solution strategies of the average, least-squares and genetic optimization algorithms are used to solve the coefficients in the gravity deformation model to further improve position accuracy and efficiency.

Experimental validation shows that the combined position error correction method proposed in this paper significantly reduces the position errors of fastener holes from 1.106 to 0.123 mm. The total position error is reduced by 43.49% compared with the traditional mechanics theory method.

The position error correlation method could reach an accuracy of millimeter or submillimeter scale, which may not satisfy higher precision.

The proposed position error correction method has been integrated into the automatic drilling machine to ensure the drilling position accuracy.

The proposed position error method could promote the wide application of automatic drilling and riveting machining system in aerospace industry.

A combined position error correction method and the complete roadmap for error compensation are proposed. The position accuracy of fastener holes is reduced stably below 0.2 mm, which can fulfill the requirements of aero-structural assembly.

In adaptive slicing, the number of layers is drastically reduced by using sloping layer walls. For both vertical (2.5D slices) and sloping (ruled slices) outer walls, the strategies for determining slice height generally consider a number of vertical sections along the contour of a slice. Surface deviation error is calculated at these sections and slice height subsequently determined. Instead, a method is proposed which calculates error at every part of the surface. This method approximates the outer wall between two successive contours by a series of taut cubic spline patches. It is proposed that the deviation between such a patch and the actual surface is a better and more exhaustive estimate of surface error. Results show that the predicted number of slices is slightly higher than that predicted by existing methods for sloping layer walls.

An adaptive grid solution method is described for computing the time accurate solution of an unsteady flow problem. The solution method consists of three parts: a grid point redistribution method; an unsteady Euler equation solver; and a temporal coupling routine that links the dynamic grid to the flow solver. The grid movement technique is a direct curve by curve method containing grid controls that generate a smooth grid that resolves the severe solution gradients and the sharp transitions in the solution gradients. By design, the temporal coupling procedure provides a grid that does not lag the solution in time. The adaptive solution method is tested by computing the unsteady inviscid solutions for a one‐dimensional shock tube and a two‐dimensional shock vortex interaction. Quantitative comparisons are made between the adaptive solutions, theoretical solutions and numerical solutions computed on stationary grids. Test results demonstrate the good temporal tracking of the solution by the adaptive grid, and the ability of the adaptive method to capture an unsteady solution of comparable accuracy to that computed on a stationary grid containing significantly more grid points than used in the adaptive grid.

We report on the progress in the development and application of a coupled boundary element/finite volume method temperature‐forward/flux‐back algorithm developed to solve conjugate heat transfer arising in 3D film‐cooled turbine blades. We adopt a loosely coupled strategy where each set of field equations is solved to provide boundary conditions for the other. Iteration is carried out until interfacial continuity of temperature and heat flux is enforced. The NASA‐Glenn explicit finite volume Navier‐Stokes code Glenn‐HT is coupled to a 3D BEM steady‐state heat conduction solver. Results from a CHT simulation of a 3D film‐cooled blade section are compared with those obtained from the standard two temperature model, revealing that a significant difference in the level and distribution of metal temperatures is found between the two. Finally, current developments of an iterative strategy accommodating large numbers of unknowns by a domain decomposition approach is presented. An iterative scheme is developed along with a physically‐based initial guess and a coarse grid solution to provide a good starting point for the iteration. Results from a 3D simulation show the process that converges efficiently and offers substantial computational and storage savings.

The purpose of the current paper is to develop a numerical methodology, based on the immersed boundary-lattice Boltzmann computational framework, for the Neumann and Dirichlet boundary conditions in problems involving natural and forced convection heat transfer.

The direct forcing immersed boundary method is extended to study the heat transfer by incompressible flow within the thermal lattice Boltzmann method (LBM) computational framework. The direct forcing and heating immersed boundary-LBM introduces a heat source term to the thermal LBM to account for the heat transfer occurring at the immersed boundary. New numerical treatments for the Neumann type of boundary condition and for the calculation of the local Nusselt number are developed. The developed methodologies have been applied to flows around immersed bodies with natural and forced convection, including steady as well as unsteady flows.

Numerical experiments involving immersed bodies in natural and forced convection have been performed in order to assess the validity of the direct heating IB-LBM. The flow cases studied also include steady and transient flow phenomena. Flow velocity field and isotherms have been used for qualitative comparisons with existing, published results. The surface averaged Nusselt number, Strouhal number, and lift coefficient (for the unsteady flow cases) have been used for quantitative comparison with published results. The results show that there are satisfactory agreements, qualitatively and quantitatively, between the results obtained by using the present method and those previously published.

Limited application of immersed boundary to thermal flows within the LBM has been studied by researchers; the few past studies were limited to Dirichlet boundary conditions and/or using of feedback forcing and heating approaches. In the current paper, the direct forcing and heating approach was used which helps to eliminate the arbitrary constants used in the feedback approaches. The developed new numerical treatments for the Neumann type of boundary condition and for the calculation of the local Nusselt number eliminate the need to determine surface normal and temperature gradient in the normal direction for heat transfer calculation, which is particularly beneficial in cases with deforming or changing boundaries.

In this work, a mortar method is implemented for tying arbitrary dissimilar 3D meshes, i.e. 3D meshes with curved, non‐matching interfaces. The 3D method requires approximations to the surface integrals specified by the projection of the displacement jump across the interface onto the Lagrange multiplier space. The numerical integration scheme is presented and several Lagrange multiplier interpolation schemes are considered. Furthermore, some implementational issues such as how to handle boundary conditions will be described such that stability is retained. Finally, the implementation will be demonstrated in numerical simulations and comparison of different formulations will be made.

A flux‐difference splitting based on the polynomial character of the flux vectors is applied to steady Euler equations, discretized with a vertex‐centred finite volume method. In first order accurate form, a discrete set of equations is obtained which is both conservative and positive. Due to the positivity, the set of equations can be solved by collective relaxation methods in multigrid form. A full multigrid method based on successive relaxation, full weighting, bilinear interpolation and W‐cycle is used. Second order accuracy is obtained by the Chakravarthy‐Osher flux‐extrapolation technique, using the Roe‐Chakravarthy minmod limiter. In second order form, direct relaxation of the discrete equations is no longer possible due to the loss of positivity. A defect‐correction is used in order to solve the second order system.

A fully mixed hybrid 4‐node shell element for linear analyses is presented and compared to the current state‐of‐the‐art. The specific improvements developed concern the stress assumptions for the transverse shear stresses in the in‐plane directions, such that the element is applicable for arbitrary element geometries without shear locking and satisfies the patch test exactly. Furthermore, in analogy to the membrane and bending part the shear part of the stiffness matrix can be formulated as a one‐point integrated constant part with a rank‐two update representing the linear parts. However, this efficient formulation leads to additional approximations concerning the geometry of arbitrarily curved elements. The latter aspect is discussed with some numerical examples, which demonstrate the capabilities of the developed element.

The purpose of this paper is to develop a counter-extrapolation approach for computational heat and mass transfer with the interfacial discontinuity considered at conjugate interfaces.

By applying finite-difference approximations for the interfacial gradients along the local normal direction, the conjugate system can be simplified to the Dirichlet boundary problems for individual domains. A suitable method for the Dirichlet boundary value condition can then be used. The lattice Boltzmann method has been used to demonstrate the method. The model has been carefully validated by comparing the simulation results and theoretical solutions for steady and unsteady systems with flat or circular interfaces. Furthermore, the cooling process of a hot cylinder in a cold flow, which involves unsteady flow and heat transfer across a curved interface, has been simulated as an example to illustrate the practical usefulness of this model.

Good agreement has been observed in comparisons of simulations and theoretical solutions. The convergence and stability of the method have also been examined and satisfactory results have been obtained. Results of the cylinder cooling process show that a surface insulation layer can effectively reduce the heat transfer process and slow down the cooling process.

This method possesses several technical advantages, including the simple and straightforward algorithm, and accurate representation of the interface geometry. The basic idea and algorithm of the counter-extrapolation procedure presented here can be readily extended to other lattice Boltzmann models and even other computational technologies for heat and mass transfer systems with interface discontinuity.

Methods that use spatial gradients of enthalpy to evaluate effective specific heats and capture latent heat effects in phase change problems have been used successfully in finite element formulations based on linear interpolation. In view of the greater geometrical flexibility and efficiency of biquadratic isoparametric elements, it is of interest to assess the use of the methods with these elements. In comparisons with an accurate semi‐analytic solution for a test problem, it is shown that the enthalpy gradient methods with quadratic interpolation are prone to error. A new procedure is proposed that uses bilinear sub‐elements for enthalpy, formed by subdivision of the biquadratic temperature elements. This is shown to be accurate and robust, for phase change intervals as small as 0.02°C.