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In this paper, a novel and unified method for geometry configuration simulation of flexible cable under certain boundary conditions is presented. This methodology can be used to realize cable assembly verification in any computer-aided design/manufacturing system. The modeling method, solution algorithm, geometry configuration simulation and experimental results are presented to prove the feasibility of this proposed methodology. The paper aims to discuss these issues.

Considering the gravity, bending and torsion, modeling of cable follows the Kirchhoff theory. For this purpose, Euler quaternions are used to describe its spatial geometry configuration by a carefully chosen set of coordinates. Then the cable is discretized by the FEM, and the equilibrium condition per element is computed. In this way, the global static behavior is independent of the discretization. The static evolution of the cable is obtained by numerical integration of the resulting Kirchhoff equations. Then the manner is demonstrated, in which this system of equations can be decoupled and efficiently solved. Geometry configuration simulation examples with different boundary conditions are presented. Finally, experiment validation are given to describe the effectiveness of the models and algorithms.

The method presented in this paper can be adapted to computer-aided assembly verification of flexible cable. The experimental results indicate that both of the model and algorithm are efficient and accurate.

The method should be extended to flexible cables with multiple branches and more complex constraints (holes, curved surfaces and clamps) and non-circular sections. Dynamic assembly process simulation based on the Kirchhoff theory must be considered in the future.

Unlike in previous approaches, the cable behavior was independent of the underlying discretization, and the finite element approach enables physically plausible cable assembly verification.

Recent work has demonstrated the possibility of selectively sintering polymer powders with radio frequency (RF) radiation as a means of rapid, volumetric additive manufacturing. Although RF radiation can be used as a volumetric energy source, non-uniform heating resulting from the sample geometry and electrode configuration can lead to adverse effects in RF-treated samples. This paper aims to address these heating uniformity issues by implementing a computational design strategy for doped polymer powder beds to improve the RF heating uniformity.

Two approaches for improving the RF heating uniformity are presented with the goal of developing an RF-assisted additive manufacturing process. Both techniques use COMSOL Multiphysics® to predict the temperature rise during simulated RF exposure for different geometries. The effectiveness of each approach is evaluated by calculating the uniformity index, which provides an objective metric for comparing the heating uniformity between simulations. The first method implements an iterative heuristic tuning strategy to functionally grade the electrical conductivity within the sample. The second method involves reorienting the electrodes during the heating stage such that the electric field is applied in two directions.

Both approaches are shown to improve the heating uniformity and predicted part geometry for several test cases when applied independently. However, the greatest improvement in heating uniformity is demonstrated by combining the approaches and using multiple electrode orientations while functionally grading the samples.

This work presents an innovative approach for overcoming RF heating uniformity issues to improve the resulting part geometry in an RF-assisted, volumetric additive manufacturing method.

The mixing of fuel and air plays a pivotal role in enhancing combustion in supersonic regime. Proper mixing stabilizes the flame and prevents blow-off. Blow-off is due to the shorter residence time of fuel and air in the combustor, as the flow is in supersonic regime. The flame is initiated in the local subsonic region created using a flameholder within the supersonic combustor. This study aims to design an effective flameholder which increases the residence time of fuel in the combustor allowing proper combustion preventing blow-off and other instabilities.

The geometry of the strut-based flameholder is altered in the present study to induce a streamwise motion of the fluid downstream of the strut. The streamwise motion of the fluid is initiated by the ramps and grooves of the strut geometry. The numerical simulations were carried out using ANSYS Fluent and are validated against the available experimental and numerical results of cold flow with hydrogen injection using plain strut as the flameholder. In the present study, numerical investigations are performed to analyse the effect on hydrogen injection in strut-based flameholders with ramps and converging grooves using Reynolds-averaged Navier–Stokes equation coupled with Menter’s shear stress transport k-ω turbulence model. The analysis is done to determine the effect of geometrical parameters and flow parameter on the flow structures near the base of the strut where thorough mixing takes place. The geometrical parameters under consideration include the ramp length, groove convergence angle, depth of the groove, groove compression angle and the Mach number. Two different strut configurations, namely, symmetric and asymmetric struts were also studied.

Higher turbulence and complex flow structures are visible in asymmetric strut configuration which develops better mixing of hydrogen and air compared to symmetric strut configuration. The variation in the geometric parameters develop changes in the fluid motion downstream of the strut. The fluid passing through the converging grooves gets decelerated thereby reducing the Mach number by 20% near the base of the strut compared to the straight grooved strut. The shorter ramps are found to be more effective, as the pressure variation in lateral direction is carried along the strut walls downstream of the strut increasing the streamwise motion of the fluid. The decrease in the depth of the groove increases the recirculation zone downstream of the strut. Moreover, the increase in the groove compression angle also increases the turbulence near the base of the strut where the fuel is injected. Variation in the injection port location increases the mixing performance of the combustor by 25%. The turbulence of the fuel jet stream is considerably changed by the increase in the injection velocity. However, the change in the flow field properties within the flow domain is marginal. The increase in fuel mass flow rate brings about considerable change in the flow field inducing stronger shock structures.

The present study identifies the optimum geometry of the strut-based flameholder with ramps and converging grooves. The reaction flow modelling may be performed on the strut geometry incorporating the design features obtained in the present study.

This study aims to examine the feasibility of feedforward actuation of the recoater blade position to alleviate the resin surface non-uniformity while moving over deep-to-shallow transitions of submerged (already cured) geometric features.

A two-dimensional computational fluid dynamics (CFD) model has been used to determine optimized blade actuation protocols to minimize the resin surface non-uniformity. An experimental setup has been designed to validate the feasibility of the proposed protocol in practice.

A developed protocol for the blade height actuation is applied to a rectangular stair-like configuration of the underlying part geometry. The evaluation of the actuation protocol revealed the importance of two physical length scales, the capillary length and the size of the flow recirculation cell below in the liquid resin layer below the blade. They determine, together with the length scales defining the topography (horizontal extent and depth), the optimal blade trajectory. This protocol has also shown its efficiency for application to more complicated shapes (and, potentially, for any arbitrary geometry).

This study shows that incorporation of a feedforward control scheme in the recoating system might significantly reduce (by up to 80%) the surface unevenness. Moreover, this improvement of performances does not require major modifications of the existing architecture.

The results presented in this work demonstrate the benefits of the integration of the feedforward control to minimize the leading edge bulges over underlying part geometries in stereolithography.

High pressure die casting is a widely used industrial process to manufacture complex-shaped products in light alloys. Virtual prototyping techniques, especially numeric-based simulations of the casting process, allow the die filling process to be evaluated and help faster optimization of the gating system, which is the most critical element of the mould. The purpose of this paper is to present a four step approach to design optimal moulds taking advantage of the simulation tools.

No formalized method to design an optimal gating system is available yet and the majority of the studies aim to optimize existing geometries or to choose from alternative solutions. Rather than optimizing the geometries of predefined designs by running attempt trials, the proposed approach defines a procedure to position cavities, gating systems and, finally, to determine the whole mould geometry.

The approach is demonstrated through three different industrial applications. The design of a six-cavity mould for gas cooking burners is reported at first. Then, two test cases, a cup and a radiator, are reported for showing different arrangements of the gating system. The reached quality of the mould design has been assessed using metallographic analyses of the casts.

The design of a mould is strictly correlated to its product and mainly based on a trial-and-error approach. Numerical simulations offer a powerful and not expensive way to study the effectiveness of different die designs and filling processes. The paper proposes a structured approach for the definition of the gating system. It ultimately leads to improvements in both product quality and process productivity, including more effective control of the die filling and die thermal performance.

Two-dimensional incompressible fluid flows around a rectangular shape placed over a larger rectangular shape at low Reynolds numbers (Re) have been numerically analyzed in the present work. The vortex shedding is investigated at different arrangements of the two shapes allowing the investigation of three possible configurations. The calculations are carried out for several values of Re ranging from 1 to 200. The effect of the obstacle geometry on the vortex shedding is analyzed for crawling, steady and unsteady regimes. The analysis of the flow evolution shows that with increasing Re beyond a certain critical value, the flow becomes unstable and undergoes a bifurcation. This paper aims to observe that the transition of the unsteady regime is performed by a Hopf bifurcation. The critical Re beyond which the flow becomes unsteady is determined for each configuration. A special attention is paid to compute the drag and lift forces acting on the rectangular shapes, which allowed determining; the best configuration in terms of both drag and lift. The unsteady periodic wake is characterized by the Strouhal number, which varies with the Re and the obstacle geometry. Hence, the values of vortex shedding frequencies are calculated in this work.

The dimensionless Navier–Stokes equations were numerically solved using the following numerical technique based on the finite volume method. The temporal discretization of the time derivative is performed by an Euler backward second-order implicit scheme. Non-linear terms are evaluated explicitly; while, viscous terms are treated implicitly. The strong velocity–pressure coupling present in the continuity and the momentum equations are handled by implementing the projection method.

The present paper aims to numerically study the effect of the obstacle geometry on the vortex shedding and on the drag and lift forces to analyze the flow structure around three configurations at crawling, steady and unsteady regimes.

A special attention is paid to compute the drag and lift forces acting on the rectangular shapes, which allowed determining; the best shapes configuration in terms of both drag and lift.

This paper aims to investigate the feasibility of supportless printing of lattice structures by metal fused filament fabrication (MF³) of Ti-6Al-4V. Additionally, an empirical method was presented for the estimation of extrudate deflection in unsupported regions of lattice cells for different geometric configurations.

Metal-polymer feedstock with a solids-loading of 59 Vol.% compounded and extruded into a filament was used for three-dimensional printing of lattice structures. A unit cell was used as a starting point, which was then extended to multi-stacked lattice structures. Feasible MF³ processing conditions were identified to fabricate defect-free lattice structures. The effects of lattice geometry parameters on part deflection and relative density were investigated at the unit cell level. Computational simulations were used to predict the part quality and results were verified by experimental printing. Finally, using the identified processing and geometry parameters, multi-stacked lattice structures were successfully printed and sintered.

Lattice geometry required considerable changes in MF³ printing parameters as compared to printing bulk parts. Lattice cell dimensions showed a considerable effect on dimensional variations and relative density due to varying aspect ratios. The experimental printing of lattice showed large deflection/sagging in unsupported regions due to gravity, whereas simulation was unable to estimate such deflection. Hence, an analytical model was presented to estimate extrudate deflections and verified with experimental results. Lack of diffusion between beads was observed in the bottom facing surface of unsupported geometry of sintered unit cells as an effect of extrudate sagging in the green part stage. This study proves that MF³ can fabricate fully dense Ti-6Al-4V lattice structures that appear to be a promising candidate for applications where mechanical performance, light-weighting and design customization are required.

Supportless printing of lattice structures having tiny cross-sectional areas and unsupported geometries is highly challenging for an extrusion-based additive manufacturing (AM) process. This study investigated the AM of Ti-6Al-4V supportless lattice structures using the MF³ process for the first time.

In this study, a modeling method for a clamped deformable cable simulation based on Kirchhoff theory is proposed. This methodology can be used to describe the physical deformation configuration of any constrained flexible cable in a computer-aided design/manufacturing system. The modeling method, solution algorithm, simulation and experimental results are presented to prove the feasibility of the proposed methodology. The paper aims to discuss these issues.

First, Kirchhoff equations for deformable cables are proposed based on the nonlinear mechanics of thin elastic rods, and the general solution of the equations described by the Euler angles is given in the arc coordinate system. The parametric form solution of the Kirchhoff equations, which is easy to use, is then obtained in a cylindrical coordinate form based on Saint Venant’s theory. Finally, mathematical expressions that reflect the clamped cable configuration are given, and the deformable process is simulated based on an open source geometry kernel and is then tested by a 3D laser scanning technology.

The method presented in this paper can be adapted to any boundary condition for constrained cables as long as the external force and torque are known. The experimental results indicate that both the model and algorithm are efficient and accurate.

A more comprehensive study must be executed for the physical simulation of more complicated constrained cables, such as the helical spring and asymmetric constraint. The influence of the material properties of the cable on the calculation efficiency must be considered in future analysis.

The semi-analytical algorithm of the cable simulation in cylindrical coordinates is a novel topic and is more accurate and efficient than the common numerical solution.

Because of the anisotropy of the process and the variability in the quality of printed parts, finite element analysis is not directly applicable to recycled materials manufactured using fused filament fabrication. The purpose of this study is to investigate the numerical-experimental mechanical behavior modeling of the recycled polymer, that is, recyclable polyethylene terephthalate (rPET), manufactured by a deposition FFF process under compressive stresses for new sustainable designs.

In all, 42 test specimens were manufactured and analyzed according to the ASTM D695-15 standards. Eight numerical analyzes were performed on a real design manufactured with rPET using Young's compression modulus from the experimental tests. Finally, eight additional experimental tests under uniaxial compression loads were performed on the real sustainable design for validating its mechanical behavior versus computational numerical tests.

As a result of the experimental tests, rPET behaves linearly until it reaches the elastic limit, along each manufacturing axis. The results of this study confirmed the design's structural safety by the load scenario and operating boundary conditions. Experimental and numerical results show a difference of 0.001–0.024 mm, allowing for the rPET to be configured as isotropic in numerical simulation software without having to modify its material modeling equations.

The results obtained are of great help to industry, designers and researchers because they validate the use of recycled rPET for the ecological production of real-sustainable products using MEX technology under compressive stress and its configuration for numerical simulations. Major design companies are now using recycled plastic materials in their high-end designs.

Validation results have been presented on test specimens and real items, comparing experimental material configuration values with numerical results. Specifically, to the best of the authors’ knowledge, no industrial or scientific work has been conducted with rPET subjected to uniaxial compression loads for characterizing experimentally and numerically the material using these results for validating a real case of a sustainable industrial product.

Discusses the 27 papers in ISEF 1999 Proceedings on the subject of electromagnetisms. States the groups of papers cover such subjects within the discipline as: induction machines; reluctance motors; PM motors; transformers and reactors; and special problems and applications. Debates all of these in great detail and itemizes each with greater in‐depth discussion of the various technical applications and areas. Concludes that the recommendations made should be adhered to.