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This study aims to optimize the manufacturing process to improve the manufacturing quality, costs and delivering time with the help of multiscale multiphysics modelling and simulation. Multiscale multiphysics-based modelling and simulations are receiving more and more interest by research community and the industry particularly in the context of increasing demands for manufacturing high precision complex products and understanding the intrinsic complexity in associated manufacturing processes.

In this paper, some modelling and analysis techniques using multiscale multiphysics modelling are presented and discussed.

Furthermore, the possibility of adopting the multiscale multiphysics modelling and simulation to develop the virtual machining system is evaluated, and further supported with an industrial case study on abrasive flow machining (AFM) of integrally bladed rotors using the techniques and system developed.

With the development of multiscale multiphysics-based modelling and simulation, it will enable effective and efficient optimisation of manufacturing processes and further improvement of manufacturing quality, costs, delivery time and the overall competitiveness.

This paper aims to present a geometrical void model in conjunction with a multiscale method to evaluate the effect of interraster distance, bead (raster) width and layer height, on the voids concentration (volume) and subsequently calculate the final mechanical properties of the fused deposition modeling parts at constant infill.

A geometric model of the voids inside the representative volume element (RVE) is combined with a two-scale asymptotic homogenization method. The RVEs are subjected to periodic boundary conditions solved by finite element (FE) to calculate the effective mechanical properties of the corresponding RVEs. The results are validated with literature and experiments.

Bead width from 0.2 to 0.3 mm, reported a decrease of 25% and 24% void volume for a constant layer height (0.1 and 0.2 mm – 75% infill). It is reported that the void’s volume increased up to 14%, 32% and 36% for 75%, 50% and 25% infill by varying layer height (0.1–0.2  and 0.3 mm), respectively. For elastic modulus, 14%, 9% and 10% increase is reported when the void’s volume is decreased from 0.3 to 0.1 mm at a constant 75% infill density. The bead width and layer height have an inverse effect on voids volume.

This work brings values: a multiscale-geometric model capable of predicting the voids controllability by varying interraster distance, layer height and bead width. The idealized RVE generation slicer software and Solidworks save time and cost (<10 min, $0). The proposed model can effectively compute the mechanical properties together with the voids analysis.

This paper aims to introduce a multiscale computational method for structural failure analysis with inheriting simulation of moving trans-scale boundary (MTB). This method is motivated from the error in domain bridging caused by cross-scale damage evolution, which is common in structural failure induced by damage accumulation.

Within the method, vulnerable regions with high stress level are described by continuum damage mechanics, while elastic structural theory is sufficient for the rest, dividing the structural model into two scale domains. The two domains are bridged to generate mixed dimensional finite element equation of the whole system. Inheriting simulation is developed to make the computation of MTB sustainable.

Numerical tests of a notched three-point bending beam and a steel frame show that this MTB method can improve efficiency and ensure accuracy while capturing the effect of material damage on deterioration of components and structure.

The proposed MTB method with inheriting simulation is an extension of multiscale simulation to structural failure analysis. Most importantly, it can deal with cross-scale damage evolution and improve computation efficiency significantly.

This paper aims to extend the hybrid atomistic-continuum multiscale method developed by Vu et al. (2016) to study the gas flow problems in long microchannels involving density variations.

The simulation domain is decomposed into three regions: the bulk where the continuous Navier–Stokes and energy equations are solved, the neighbourhood of the wall simulated by molecular dynamics and the overlap region which connects the macroscopic variables (density, velocity and temperature) between the two former regions. For the simulation of long micro/nanochannels, a strategy with multiple molecular blocks all along the fluid/solid interface is adopted to capture accurately the macroscopic velocity and temperature variations.

The validity of the hybrid method is shown by comparisons with a simplified analytical model in the molecular region. Applications to compressible and condensation problems are also presented, and the results are discussed.

The hybrid method proposed in this paper allows cost-effective computer simulations of large-scale problems with an accurate modelling of the transfers at small scales (velocity slip, temperature jump, thin condensation films, etc.).

This paper aims to present a hierarchical multiscale model to evaluate the effect of fused deposition modeling (FDM) process parameters on mechanical properties. Asymptotic homogenization mathematical theory is developed into two scales (micro and macro scales) to compute the effective elastic and shear modulus of the printed parts. Four parameters, namely, raster orientation, layer height, build orientation and porosity are studied.

The representative volume elements (RVEs) are generated by mimicking the microstructure of the printed parts. The RVEs subjected to periodic boundary conditions were solved using finite element. The experimental characterization according to ASTM D638 was conducted to validate the computational modeling results.

The computational model reports reduction (E1, ∼>38%) and (G12, ∼>50%) when porosity increased. The elastic modulus increases (1.31%–47.68%) increasing the orthotropic behavior in parts. Quasi-solids parts (100% infill) possess 10.71% voids. A reduction of 11.5% and 16.5% in elastic modulus with layer height is reported. In total, 45–450 oriented parts were highly orthotropic, and 0–00 parts were strongest. The order of parameters affecting the mechanical properties is porosity > layer height > raster orientation > build orientation.

This study adds value to the state-of-the-art terms of construction of RVEs using slicing software, discarding the necessity of image processing and study of porosity in FDM parts, reporting that the infill density is not the only measure of porosity in these parts.

The purpose of this paper is to investigate thermal properties at Cu/Al interfaces.

A hybrid (molecular dynamics-interface stress element-finite element model (MD-ISE-FE) model is constructed to describe thermal behaviors at Cu/Al interfaces. The heat transfer simulation is performed after the non-ideal Cu/Al interface is constructed by diffusion bonding.

The simulation shows that the interfacial thermal resistance is decreasing with the increase of bonding temperature; while the interfacial region thickness and interfacial thermal conductivity are increasing with similar trends when the bonding temperature is increasing. It indicates that the higher bonding temperature can improve thermal properties of the interface structure.

The MD-ISE-FE model proposed in this paper is computationally efficient for interfacial heat transfer problems, and could be used in investigations of other interfacial behaviors of dissimilar materials. All these are helpful for the understanding of thermal properties of wire bonding interface structures. It implies that the MD-ISE-FE multiscale modeling approach would be a potential method for design and analysis of interfacial characteristics in micro/nano assembly.

The purpose of this paper is to develop a discrete element (DE) and multiscale modeling methodology to represent granular media at their particle scale as they interface solid deformable bodies, such as soil‐tool, tire, penetrometer, pile, etc., interfaces.

A three‐dimensional ellipsoidal discrete element method (DEM) is developed to more physically represent particle shape in granular media while retaining the efficiency of smooth contact interface conditions for computation. DE coupling to finite element (FE) facets is presented to demonstrate initially the development of overlapping bridging scale methods for concurrent multiscale modeling of granular media.

A closed‐form solution of ellipsoidal particle contact resolution and stiffness is presented and demonstrated for two particle, and many particle contact simulations, during gravity deposition, and quasi‐static oedometer, triaxial compression, and pile penetration. The DE‐FE facet coupling demonstrates the potential to alleviate artificial boundary effects in the shear deformation region between DEM granular media and deformable solid bodies.

The research is being extended to couple more robustly the ellipsoidal DEM code and a higher order continuum FE code via overlapping bridging scale methods, in order to remove dependence of penetration/shear resistance on the boundary placement for DE simulation.

When concurrent multiscale computational modeling of interface conditions between deformable solid bodies and granular materials reaches maturity, modelers will be able to simulate the mechanical behavior accounting for physical particle sizes and flow in the interface region, and thus design their tool, tire, penetrometer, or pile accordingly.

A closed‐form solution for ellipsoidal particle contact is demonstrated in this paper, and the ability to couple DE to FE facets.

Multiple length and time scales arise in a wide variety of practical and fundamental problems. It is important to obtain accurate and validated numerical simulation results, considering the different scales that exist, in order to predict, design and optimize the behavior of practical thermal processes and systems. The purpose of this paper is to present modeling at the different length scales and then addresses the question of coupling the different models to obtain the overall model for the system or process.

Both numerical and experimental methods to obtain results at the different length scales, particularly at micro and nanoscales, are considered. Even though the paper focusses on length scales, multiple time scales lead to similar concerns and are also considered. The two circumstances considered in detail are multiple length scales in different domains and those in the same domain. These two cases have to be modeled quite differently in order to obtain a model for the overall process or system. The basic considerations involved in such a modeling are discussed. A wide range of thermal processes are considered and the methods that may be used are presented. The models employed must be validated and the accuracy of the simulation results established if the simulation results are to be used for prediction, control and design.

Of particular interest are concerns like verification and validation, imposition of appropriate boundary conditions, and modeling of complex, multimode transport phenomena in multiple scales. Additional effects such as viscous dissipation, surface tension, buoyancy and rarefaction that could arise and complicate the modeling are discussed. Uncertainties that arise in material properties and in boundary conditions are also important in design and optimization. Large variations in the geometry and coupled multiple regions are also discussed.

The paper is largely focussed on multiple-scale considerations in thermal processes. Both numerical modeling/simulation and experimentation are considered, with the latter being used for validation and physical insight.

Several examples from materials processing, environmental flows and electronic systems, including data centers, are given to present the different techniques that may be used to achieve the desired level of accuracy and predictability.

Present state of the art and future needs in this interesting and challenging area are discussed, providing the impetus for further work. Different methods for treating multiscale problems are presented.

Evaluating mechanical properties of simply made samples by 3D printing technology at nanoscale provides a clear path to better understand larger-scale responses of complex natural rocks. Therefore, to realize the similarity between synthetically manufactured materials and natural geomaterials, this study focused on nanoscale mechanical characterization of a 3D printed object with only two constituent components (gypsum powder and infiltrant).

The study method includes nanoindentation technique combined with numerical simulation via discrete element method (DEM).

Four typical load-displacement curves were identified from nanoindentation of total test points indicating a typical elastic-plastic behavior of the 3D printed gypsum rock sample. Mechanical parameters such as Young’s modulus and hardness were calculated by energy-based methods and a positive correlation was observed. The infiltrant was found to considerably be responsible for the majority of the sample nano-mechanical behavior rather than the gypsum particles, thus expected to control macroscale properties. This was decided from deconvolution and clustering of elastic modulus data. Particle flow modeling in DEM was used to simulate the nanoindentation process in a porous media yielding rock-alike mechanical behavior.

The results show a matching load-displacement response between experimental and simulation results, which verified the credibility of simulation modeling for mechanical behavior of 3D printed gypsum rock at nanoscale. Finally, differential effective medium theory was used to upscale the nanoindentation results to the macroscale mechanical properties, which provided an insight into the geomechanical modeling at multiscale.

Additive manufacturing (AM) is revolutionizing the manufacturing industry due to several advantages and capabilities, including use of rapid prototyping, fabrication of complex geometries, reduction of product development cycles and minimization of material waste. As metal AM becomes increasingly popular for aerospace and defense original equipment manufacturers (OEMs), a major barrier that remains is rapid qualification of components. Several potential defects (such as porosity, residual stress and microstructural inhomogeneity) occur during layer-by-layer processing. Current methods to qualify AM parts heavily rely on experimental testing, which is economically inefficient and technically insufficient to comprehensively evaluate components. Approaches for high fidelity qualification of AM parts are necessary.

This review summarizes the existing powder-based fusion computational models and their feasibility in AM processes through discrete aspects, including process and microstructure modeling.

Current progresses and challenges in high fidelity modeling of AM processes are presented.

Potential opportunities are discussed toward high-level assurance of AM component quality through a comprehensive computational tool.