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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 paper gives the description of boundary element method (BEM) with subdomains for the solution of convection—diffusion equations with variable coefficients and Burgers’ equations. At first, the whole domain is discretized into K subdomains, in which linearization of equations by representing convective velocity by the sum of constant and variable parts is carried out. Then using fundamental solutions for convection—diffusion linear equations for each subdomain the boundary integral equation (in which the part of the convective term with the constant convective velocity is not included into the pseudo‐body force) is formulated. Only part of the convective term with the variable velocity, which is, as a rule, more than one order less than convective velocity constant part contribution, is left as the pseudo‐source. On the one hand, this does not disturb the numerical BEM—algorithm stability and, on the other hand, this leads to significant improvement in the accuracy of solution. The global matrix, similar to the case of finite element method, has block band structure whereas its width depends only on the numeration order of nodes and subdomains. It is noted, that in comparison with the direct boundary element method the number of global matrix non‐zero elements is not proportional to the square of the number of nodes, but only to the total number of nodal points. This allows us to use the BEM for the solution of problems with very fine space discretization. The proposed BEM with subdomains technique has been used for the numerical solution of one‐dimensional linear steady‐state convective—diffusion problem with variable coefficients and one‐dimensional non‐linear Burgers’ equation for which exact analytical solutions are available. It made it possible to find out the BEM correctness according to both time and space. High precision of the numerical method is noted. The good point of the BEM is the high iteration convergence, which is disturbed neither by high Reynolds numbers nor by the presence of negative velocity zones.

A numerical study of natural convection of air in a vertical annulus has been conducted, where the inner wall is heated with constant heat flux at its inner side, the outer wall of the annulus being maintained at constant temperature, and the top and bottom plates are assumed to be insulated. The cases of radius ratio K = 3, aspect ratio A = 10∼30, and Ra* = 103∼1.7 × 107 have been simulated. Both axial conduction and surface radiation are taken into account to reveal their effects on the distributions of inner wall temperature and local Nusselt number. Emphasis is on the comparison between the numerical results and the relevant experimental data, and the comparison between numerical solutions with and without considering the surface radiation. The numerical results of heat transfer are found to be in good agreement with the corresponding experimental results in the literature. The dependence of average relative conductivity on aspect ratio and the effect of imperfection in top and bottom insulation on the inner wall temperature are also discussed.

This study aims to investigate the behavior of different types of stone columns, including the short and floating columns, as well as the ordinary and the geosynthetic encased stone columns (OSC and GESC). The effectiveness of the geosynthetic encasement and the impact of the installation using the lateral expansion method on the column performance is evaluated through a three-dimensional (3D) unit cell numerical analysis.

A full 3D numerical analysis is carried out using the explicit finite element code PLAXIS 3D to examine the installation influence on settlement reduction (ß), lateral displacement (U_x) and vertical displacement (U_z) relative to different values of lateral expansion of the column (0% to 15%).

The findings demonstrate the superior performance of GESC, particularly short columns outperforming floating counterparts. This enhanced performance is attributed to the combined effects of geosynthetic encasement and increased lateral expansion. Notably, these strategies contribute significantly to decreasing lateral displacement (U_x) at the column’s edge and reducing vertical displacement (U_z) under the rigid footing.

In contrast to previous studies that examined the installation effect of OSC contexts, this paper presents a comprehensive investigation into the effect of geosynthetic encasement and the installation effects using the lateral expansion method in very soft soil, using 3D numerical simulation. The study emphasizes the significance of the consideration of geosynthetic encasement and lateral expansion of the column during the design process to enhance column performance.

The present investigation is an extension of the authors’ previous work on ducts with different cross sections. It concerns application of turbulence models for forced convective heat transfer in three‐dimensional corrugated or wavy ducts. Different wavy ducts with fully developed flow and temperature fields are considered. The numerical approach is based on the finite volume technique with a non‐staggered grid arrangement. For handling the pressure‐velocity coupling the SIMPLEC‐algorithm is used. Cyclic boundary conditions are imposed in the main flow direction to achieve fully developed conditions. The non‐linear k‐ε model of Speziale with wall functions is used to calculate the turbulent stresses. The simple eddy diffusivity concept is applied to calculate the heat fluxes, but the GGDH and the WET methods are also used in some cases. The influence of the geometry parameters and comparison between different ducts are presented in terms of the friction factor and average Nusselt number. In particular the secondary velocity field and the cross sectional temperature distributions are investigated.

This study aims to investigate the possible defects and their root causes in a soft-termination multilayered ceramic capacitor (MLCC) when subjected to a thermal reflow process.

Specimens of the capacitor assembly were subjected to JEDEC level 1 preconditioning (85 °C/85%RH/168 h) with 5× reflow at 270°C peak temperature. Then, they were inspected using a 2 µm scanning electron microscope to investigate the evidence of defects. The reliability test was also numerically simulated and analyzed using the extended finite element method implemented in ABAQUS.

Excellent agreements were observed between the SEM inspections and the simulation results. The findings showed evidence of discontinuities along the Cu and the Cu-epoxy layers and interfacial delamination crack at the Cu/Cu-epoxy interface. The possible root causes are thermal mismatch between the Cu and Cu-epoxy layers, moisture contamination and weak Cu/Cu-epoxy interface. The maximum crack length observed in the experimentally reflowed capacitor was measured as 75 µm, a 2.59% difference compared to the numerical prediction of 77.2 µm.

This work's contribution is expected to reduce the additional manufacturing cost and lead time in investigating reliability issues in MLCCs.

Despite the significant number of works on the reliability assessment of surface mount capacitors, work on crack growth in soft-termination MLCC is limited. Also, the combined experimental and numerical investigation of reflow-induced reliability issues in soft-termination MLCC is limited. These cited gaps are the novelties of this study.

External natural convection is rarely studied by numerical simulation in the literature due to the fact that flow of interest takes place in an unbounded domain and that if a limited computational domain is used the corresponding outer boundary conditions are unknown. In this study, we propose outer boundary conditions for a limited computational domain and make the corresponding numerical implementation in the scope of a projection method combining spectral methods and domain decomposition techniques. Numerical simulations are performed for both steady natural convection about an isothermal cylinder and transient natural convection around a line‐source. An experiment is also realized in water using particle image velocimetry and thermocouples to make a comparison during transients of external natural convection around a platinum wire heated by Joule effect. Good agreement, observed between numerical simulations and experiments, validated the outer boundary conditions proposed and their numerical implementation. It is also shown that, if one tolerates prediction error, numerical results obtained remain at least reasonable in a region near the line‐source during the entire transients. We thus paved the way for numerical simulation of external natural convection although further studies remain to be done for higher heating power (higher Rayleigh number).

Aims to present recent activities in experimental investigations and numerical modelling of the induction cold crucible installation.

Temperature and velocity measurements using thermocouples and electromagnetic velocity probes were performed in aluminium melt which was used as a model melt. Measured temperature field and flow pattern were compared with transient 3D calculations based on large eddy simulation (LES) turbulence modelling scheme. Numerical results are in good coincidence with the experimental data.

The modelling results show that only 3D transient LES is able to model correctly these heat and mass transfer processes.

It is revealed that transient 3D modelling provides a universal tool for simulating convective heat and mass transfer processes in the entire melt influenced by large scale instabilities in the recirculating flows, which contain several main vortexes of the mean flow.

With the widespread use of the composites over other metallic materials in different fields of engineering, studies on damages of composite structures have assumed great importance. Among various kinds of damages, delamination is of very serious concern to composite applications. It may arise as a consequence of impact loading, stress concentration near a geometrical or material discontinuity or manufacturing defects. The presence of one or more delaminations in the composite laminate may lead to a premature collapse of the structure due to buckling at a lower level of compressive loading. So the effect of delamination on stability of composite structures needs attention and thus constitutes a problem of current interest. The purpose of this paper is to deal with both numerical and experimental investigations on buckling behaviour of single and multiple, delaminated, industry driven, woven roving glass/epoxy composite plates on clamped free clamped free (CFCF) rectangular plates.

For numerical analysis, a finite element model was developed with an eight noded two dimensional quadratic isoparametric element having five degrees of freedom per node. The elastic stiffness matrices were derived using linear first order shear deformation theory with a shear correction factor. Green's nonlinear strain equations are used to derive the geometric stiffness matrix. The computation of buckling load based on present formulation is compared with the experimental results for the effect of different parameters on critical load of the delaminated composite panels. In the experimental study, the influences of various parameters such as delamination area, fiber orientations, number of layers, aspect ratios on the buckling behaviour of single and multiple delaminated woven roving glass/epoxy composite plates were investigated. Buckling loads were measured by INSTRON 1195 machine for the delaminated composite plates.

Comparison of numerical results with experimental results showed a good agreement. Both the results revealed that the area of delaminations, fiber orientations, number of layers and aspect ratio have paramount influence on the buckling behaviour of delaminated plate.

The present study is part of Jayaram Mohanty's doctoral thesis, an original research work.

This paper aims to present a numerical investigation on laboratory-scale segmental baffles shell-and-tube heat exchanger (STHX) having various tube bundles and baffle configuration.

To discover the higher performance the thermohydraulic behavior of shell-side fluid flow with circular, elliptical and twisted oval tube bundles with segmental and inclined segmental baffled is compared. Shell side turbulent flow and heat transfer are simulated by a finite volume discretization approach using SolidWorks Flow Simulation. To achieve greater configuration performance of this device, the following two approaches is considered: using the inclined baffle with 200 angles of inclination and applying the different tube bundle.

Different parameters as heat transfer rate, pressure drop (Δp), heat transfer coefficient (h) and heat transfer coefficient to pressure drop ratio (h/Δp) are presented and discussed. Besides, for considering the effect of pressure penalty and heat transfer improvement instantaneously, the efficiency evaluation coefficient (EEC) in the fluid flow and heat transfer based on the power required to provide the real heat transfer augmentation are used.

Obtained results displayed that, at the equal mass flow rate, the twisted oval tubes with segmental baffle decrease the pressure drop 53.6% and 35.64% rather than that the circular and elliptical tubes bundle, respectively. By comparing the (h/Δp) ratio, it can result that the STHX with twisted oval tubes bundle (both segmental and inclined baffle) has better performance than other kinds of the tube bundles. Present results showed that the values of the EEC for all provided models are higher than 1, except for elliptical tube bundles with segmental baffles. The STHX with twisted oval tube bundles and segmental baffle gives the highest EEC value equal to 1.16 in the range of investigated mass flow.