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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.

The purpose of this paper is to perform the computational fluid dynamics (CFD) simulation with experimental validation to investigate the particle segregation effect in abrupt and smooth shapes circulating fluidized bed (CFB) risers.

The experimental investigations were carried out in lab-scale CFB systems and the CFD simulations were performed by using commercial software BARRACUDA. Special attention was paid to investigate the gas-particle flow behavior at the top of the riser with three different superficial velocities, namely, 4, 6 and 7.7 m/s. Here, a CFD-based noble simulation approach called multi-phase particle in cell (MP-PIC) was used to investigate the effect of traditional drag models (Wen-Yu, Ergun, Wen-Yu-Ergun and Richardson-Davidson-Harrison) on particle flow characteristics in CFB riser.

Findings from the experimentations revealed that the increase in gas velocity leads to decrease the mixing index inside the riser. Moreover, the solid holdup found more in abrupt riser than smooth riser at the constant gas velocity. Despite the more experimental investigations, the findings with CFD simulations revealed that the MP-PIC approach, which was combined with different drag models could be more effective for the practical (industrial) design of CFB riser. Well agreement was found between the simulation and experimental outputs. The simulation work was compared with experimental data, which shows the good agreement (<4%).

The experimental and simulation study performed in this research study constitutes an easy-to-use with different drag coefficient. The proposed MP-PIC model is more effective for large particles fluidized bed, which can be helpful for further research on industrial gas-particle fluidized bed reactors. This study is expected to give throughout the analysis of CFB hydrodynamics with further exploration of overall fluidization.

The present work is a numerical study of a breaking dam problem. The purpose of this paper is to assess the effect of turbulence and surface tension models in the prediction of the interface position in a long-term analysis. Additionally, dimensional effects are analyzed by carrying out both 2D and 3D simulations.

Finite volume simulations performed with the different models are compared between them and contrasted with numerical results computed using other numerical techniques and experimental data.

The reported numerical results are in general in good agreement with experimental results available in the literature. They are also consistent with numerical solutions of other authors obtained using different numerical techniques. The results show that the laminar simulations exhibit strong mesh size dependency, while the turbulence models seem to help in producing mesh-independent solutions. Surface tension modeling does not seem to play a relevant role in the interface evolution.

Model validation.

The value of the present work encompass the comparison of different flow conditions used to simulate a free surface problem and their validation by contrasting numerical results with experiments. Also, the results shown in the present work are a contribution to the understanding of the role of some specific aspects of the models in the simulation of the proposed problem.

The particle damper is an efficient vibration control device and is widely used in engineering projects; however, the performance of such a system is very complicated and highly nonlinear. The purpose of this paper is to accurately simulate the particle damper system properly, and help to understand the underlying physical mechanics.

A high-fidelity simulation process is well established to account for all significant interactions among the particles and with the host structure system, including sliding friction, gravitational forces, and oblique impacts, based on the modified discrete element method. In this process, a suitable particle damper system is modeled, reaction forces between particle aggregates and the primary structure are incorporated, a reasonable contact force model and time step are determined, and an efficient contact detection algorithm is adopted.

The numerical results are further validated by both special computational tests and shaking table tests, with good agreements to the experimental results. The method is shown to be effective and accurate to simulate the particle damper system.

The approaches described in this paper provide an efficient numerical way to investigate complex particle damper systems.

The present work is an experimental and numerical study of a sloshing problem including baffle effects. The purpose of this paper is to assess the numerical behavior of a Lagrangian technique to track free surface flows by comparison with experiments, to report experimental data for sloshing at different conditions and to evaluate the effectiveness of baffles in limiting the wave height and the wave propagation.

Finite element simulations performed with a fixed mesh technique able to describe the free surface evolution are contrasted with experimental data. The experiments consist of an acrylic tank of rectangular section designed to attach baffles of different sizes at different distance from the bottom. The tank is filled with water and mounted on a shake table able to move under controlled horizontal motion. The free surface evolution is measured with ultrasonic sensors. The numerical results computed for different sloshing conditions are compared with the experimental data.

The reported numerical results are in general in good agreement with the experiments. In particular, wave heights and frequencies response satisfactorily compared with the experimental data for the several cases analyzed during steady state forced sloshing and free sloshing. The effectiveness of the baffles increases near resonance conditions. From the set of experiments studied, the major reduction of the wave height was obtained when larger baffles were positioned closer to the water level at rest.

Model validation: evaluation of the effectiveness of non-massive immersed baffles during sloshing.

The value of the present work encompass the numerical and experimental study of the effect of immersed baffles during sloshing under different imposed conditions and the comparison of numerical results with the experimental data. Also, the results shown in the present work are a contribution to the understanding of the role in the analysis of the proposed problem of some specific aspects of the geometry and the imposed motion.

This paper aims to investigate the effect of frictional heat on the wear of high-speed rotary lip seals in engines.

In this research paper, the authors focus on the high-speed rotating lip seal of aircraft engines. Using the hybrid lubrication theory, a thermal-fluid-solid coupled numerical simulation model is established to investigate the influence of parameters such as contact pressure distribution, temperature rise and leakage rate on the sealing performance under different operating conditions. By incorporating the Rhee wear theory and combining simulation results with experimental data, a method for predicting the wear of the rotating seal lip profile is proposed. Experimental validation is conducted using a high-speed rotating test rig.

The results indicate that as the speed increases, the rise in frictional heat leads to a decrease in the sealing performance of the lip seal contact region. The experimental results show a similar trend to the numerical simulation results, and considering the effect of frictional heat, the predicted wear of the lip seal profile aligns more closely with the actual wear curve. This highlights the importance of considering the influence of frictional heat in the analysis of rotating seal mechanisms.

This study provides a reference for the prediction of wear profiles of engine high-speed rotary lip seals.

This paper aims to report the study of a fluid buoy system that includes wave effects, with particular emphasis on validating the numerical results with experimental data.

A fluid–solid coupled algorithm is proposed to describe the motion of a rigid buoy under the effects of waves. The Navier–Stokes equations are solved with the open-source finite volume package Code Saturne, in which a free-surface capture technique and equations of motion for the solid are implemented. An ad hoc experiment on a laboratory scale is built. A buoy is placed into a tank partially filled with water; the tank is mounted into a shake table and subjected to controlled motion that promotes waves. The experiment allows for recording the evolution of the free surface at the control points using the ultrasonic sensors and the movement of the buoy by tracking the markers by postprocessing the recorded videos. The numerical results are validated by comparison with the experimental data.

The implemented free-surface technique, developed within the framework of the finite-volume method, is validated. The best-obtained agreement is for small amplitudes compatible with the waves evolving under deep-water conditions. Second, the algorithm proposed to describe rigid-body motion, including wave analysis, is validated. The numerical body motion and wave pattern satisfactorily matched the experimental data. The complete 3D proposed model can realistically describe buoy motions under the effects of stationary waves.

The novel aspects of this study encompass the implementation of a fluid–structure interaction strategy to describe rigid-body motion, including wave effects in a finite-volume context, and the reported free-surface and buoy position measurements from experiments. To the best of the authors’ knowledge, the numerical strategy, the validation of the computed results and the experimental data are all original contributions of this work.

This paper aims to present a novel approach for computing particle temperatures in simulations coupling computational fluid dynamics (CFD) and discrete element method (DEM) to predict flow and heat transfer in fluidized beds of thermally thick spherical particles.

An improved lumped formulation based on Hermite-type approximations for integrals to relate surface temperature to average temperature and surface heat flux is used to overcome the limitations of classical lumped models. The model is validated through comparisons with analytical solutions for a convectively cooled sphere and experimental data for a fixed particle bed. The coupled CFD-DEM model is then applied to simulate a Geldart D bubbling fluidized bed, comparing the results to those obtained using the classical lumped model.

The validation cases demonstrate that ignoring internal thermal resistance can significantly impact the temperature in cases where the Biot number is greater than 0.1. The results for the fixed bed case clearly demonstrate that the proposed method yields significantly improved outcomes compared to the classical model. The fluidized bed results show that surface temperature can deviate considerably from the average temperature, underscoring the importance of accurately accounting for surface temperature in convective heat transfer predictions and surface processes.

The proposed approach offers a physically more consistent simulation without imposing a significant increase in computational cost. The improved lumped formulation can be easily and inexpensively integrated into a typical DEM solver workflow to predict heat transfer for spherical particles, with important implications for various industrial applications.

The purpose of this paper is to present a methodology to assess material damage parameters for ductile crack initiation and growth ahead of a crack/notch tip in high hardening steel like AISI type 316L(N) stainless steel.

Ductile damage parameter and far field J-integral have been obtained from standard FEM analysis for a crack/notch tip undergoing large plastic deformation and resulting in crack initiation/growth. In conjunction with experimental results, the damage variable for low strength and high hardening material has been derived in terms of continuum parameters: equivalent plastic strain (ε_eq) and stress triaxiality (φ). The material parameters for damage initiation and growth in 316LN SS have been evaluated from tensile and fracture tests. With these material tensile/fracture parameters as input, elastic-plastic eXtended Finite Element Method (X-FEM) simulations were carried out on compact tension (CT) specimen geometry under varying initial stress triaxiality conditions.

The material parameters for damage initiation and growth have been assessed and calibrated by comparing the X-FEM predicted load-displacement responses with the experimental results. It is observed that the deviations in the predicted load values from the experimental data are within 6 percent for specimens with a/W=0.39, 0.55, 0.64, while for a/W=0.72, it is 17 percent.

The present study is a part of developing methods to obtain calibrated material damage parameters for crack growth simulation of components made of AISI 316L(N) stainless steel. This steel is used for fast breeder reactor-based power plant being built at Kalpakkam, India.

A laser seeker is an important element in missile guidance and control systems, responsible for target detection and tracking. Its control is, however, a challenging problem due to complex dynamics and various acting disturbances. Hence, the purpose of this study is to propose a systematic design, tuning, analysis and performance verification of a nonlinear active disturbance rejection control (ADRC) algorithm for the specific case of the laser seeker system.

The proposed systematic approach of nonlinear ADRC application to the laser seeker system consists of the following steps. The complex laser seeker control problem is first expressed as a regulation problem. Then, a nonlinear extended state observer (ESO) with varying gains is used to improve the performance of a conventionally used linear ESO (LESO), which enables better control quality in both transient and steady-state periods. In the next step, a systematic observer tuning, based on a detailed analysis of the system disturbances, is proposed. The stability of the overall control system is then verified using a describing function method. Next, the implementation of the NESO-based ADRC solution is realized in a fixed-point format using MATLAB/Simulink and Xilinx System Generator. Finally, the considered laser seeker control system is implemented in discrete form and comprehensively tested through hardware-in-the-loop (HIL) co-simulation.

Through the conducted comparative study of LESO-based and NESO-based ADRC algorithms for the laser seeker system, the advantages of the proposed nonlinear scheme are shown. It is concluded that the NESO-based ADRC scheme for the laser seeker system (with appropriate parameters tuning methodology) provides better control performance in both transient and steady-state periods. The conducted multicriteria study validates the efficacy of the proposed systematic approach of applying nonlinear ADRC to laser seeker systems.

In practice, the obtained results imply that the laser seeker system, governed by the studied nonlinear version of the ADRC algorithm, could potentially detect and track targets faster and more accurately than the system based on the common linear ADRC algorithm. In addition, the article presents the step-by-step procedure for the design, field programmable gate array (FPGA) implementation and HIL-based co-simulation of the proposed nonlinear controller, which can be used by control practitioners as one of the last validation stages before experimental tests on a real guidance system.

The main contribution of this work is the systematic procedure of applying the ADRC scheme with NESO for the specific case of the laser seeker system. It includes its design, tuning, analysis and performance verification (with simulation and FPGA hardware). The novelty of the work is also the combination and practical realization of known theoretical elements (NESO structure, NESO parameter tuning, ADRC closed-loop stability analysis) in the specific case of the laser seeker system. The results of the conducted applied research increase the current state of the art related to robust control of laser seeker systems working in disturbed and uncertain conditions.