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Remanufacturing of worn blades with various defects normally requires processes such as scanning, regenerating a geometrical reference model, additive manufacturing (AM) through laser cladding, adaptive machining and polishing and quality inspection. Unlike the manufacturing process of a new part, the most difficult problem for remanufacturing such a complex surface part is that the reference model adaptive to the worn part is no longer available or useful. The worn parts may suffer from geometrical deformation, distortion and other defects because of the effects of harsh operating conditions, thereby making their original computer aided design (CAD) models inadequate for the repair process. This paper aims to regenerate the geometric models for the worn parts, which is a key issue for implementing AM to build up the parts and adaptive machining to reform the parts. Unlike straight blades with similar cross sections, the tip geometry of the worn tip of a twist blade needs to be regenerated by a different method.

This paper proposes a surface extension algorithm for the reconstruction of a twist blade tip through the extremum parameterization of a B-spline basis function. Based on the cross sections of the scanned worn blade model, the given control points and knot vectors are firstly reconstructed into a B-spline curve D. After the extremum of each control point is calculated by extremum parameterization of a B-spline basis function, the unknown control points are calculated by substituting the extremum into the curve D. Once all control points are determined, the B-spline surface of the worn blade tip can be regenerated. Finally, the extension algorithm is implemented and validated with several examples.

The proposed algorithm was implemented and verified through the exampled blades. Through the extension algorithm, the tip geometry of the worn tip of a twist blade can be regenerated. This method solved a key problem for the repair of a twist blade tip. It provides an appropriate reference model for repairing worn blade tips through AM to build up the blade tip and adaptive machining/polishing processes to reform the blade geometry.

The extension errors for different repair models are compared and analyzed. The authors found that there are several factors affecting the accuracy of the regenerated model. When the cross-section interval and the extension length are set properly, the restoration accuracy for the blade tip can be improved, which is acceptable for the repairing.

The lack of a reference geometric model for worn blades is a significant problem when implementing blade repair through AM and adaptive machining processes. Because the geometric reference model is unavailable for the repair process, reconstruction of the geometry of a worn blade tip is the first crucial step. The authors proposed a surface extension algorithm for the reconstruction of a twist blade tip. Through the implementation of the proposed algorithm, the blade tip model can be regenerated.

Remanufacturing of worn blades with various defects is highly demeaned for the aerospace enterprises considering sustainable development. Unlike straight blades, repair of twist blades encountered a very difficult problem because the geometric reference model is unavailable for the repair processes. This paper proposed a different method to generate the reference model for the repair of a twist blade tip. With this model, repair of twist blades can be implemented through AM to build up the blade tip and adaptive machining to subtract the extra material.

The authors proposed a surface extension algorithm to reconstruct the geometric model for repair of twist blades.

Given an intersection-free mesh surface S, the paper introduces a method to thicken S into a solid H located at one side of S. By such a surface-to-solid conversion operation, industrial users are able to fabricate a designed (or reconstructed) surface by rapid prototyping.

The paper first investigates an implicit representation of the thickened solid H according to an extension of signed distance function. After that, a partial surface reconstruction algorithm is proposed to generate the boundary surface of H, which retains the given surface S on the resultant surface.

Experimental tests show that the thickening results generated by the method give nearly uniform thickness and meanwhile do not present shape approximation error at the region of input surface S. These two good properties are important to the industrial applications of solid fabrication.

The input polygonal model is assumed to be intersection-free, where models containing self-intersection will lead to invalid thickening results.

A novel robust operation is to convert a freeform open surface into a solid by introducing no shape approximation error. A new implicit function gives a compact mathematical representation, which can easily handle the topological change on the thickened solids. A new polygonization algorithm generates faces for the boundary of thickened solid meanwhile retaining faces on the input open mesh.

Many practical problems in engineering require fast, accurate numerical results. In particular, in cyclic plasticity or fatigue simulations, the high number of loading cycles increases the computation effort and time. The purpose of this study is to show that the return mapping technique in the framework of unconventional plasticity theories is a good compromise between efficiency and accuracy in finite element analyses.

The accuracy of the closest point projection method and the cutting plane method implementations for the subloading surface model are discussed under different loading conditions by analyzing the error as a function of the input step size and the efficiency of the algorithms.

Monotonic tests show that the two different implicit integration schemes have the same accuracy and are in good agreement with the solution obtained using an explicit forward Euler scheme, even for large input steps. However, the closest point projection method seems to describe better the evolution of the similarity centre in the cyclic loading analyses.

The purpose of this work is to show two alternative implicit integration schemes of the extended subloading surface method for metallic materials. The backward Euler integrations can guarantee a good description of the material behaviour and, at the same time, reduce the computational cost. This aspect is particularly important in the field of low or high cycle fatigue, because of the large number of cycles involved.

A detailed description of both the cutting plane and closest point projection methods is offered in this work. In particular, the two integrations schemes are compared in terms of accuracy and computation time for monotonic and cyclic loading tests.

This paper reports on the work done to decompose a large sized solid model into smaller solid components for rapid prototyping technology. The target geometric domain of the solid model includes quadrics and free form surfaces.

The decomposition criteria are based on the manufacturability of the model against a user‐defined manufacturing chamber size and the maintenance of geometrical information of the model. In the proposed algorithm, two types of manufacturing chamber are considered: cylindrical shape and rectangular shape. These two types of chamber shape are commonly implemented in rapid prototyping machines.

The proposed method uses a combination of the regular decomposition (RD)‐method and irregular decomposition (ID)‐method to split a non‐producible solid model into smaller producible subparts. In the ID‐method, the producible feature group decomposition (PFGD)‐method focuses on the decomposition by recognising producible feature groups. In the decomposition process, less additional geometrical and topological information are created. The RD‐method focuses on the splitting of non‐producible sub‐parts, which cannot be further decomposed by the PFGD‐method. Different types of regular split tool surface are studied.

Combination of the RD‐method and the ID‐method makes up the proposed volume decomposition process. The user can also define the sequence and priority of using these methods manually to achieve different decomposition patterns. The proposed idea is also applicable to other decomposition algorithm. Some implementation details and the corresponding problems of the proposed methods are also discussed.

This article focuses on the comparative study of annular wire‐coating flows with polymer melt materials. Different process designs are considered of pressure‐ and tube‐tooling, complementing earlier studies on individual designs. A novel mass‐balance free‐surface location technique is proposed. The polymeric materials are represented via shear‐thinning, differential viscoelastic constitutive models, taken of exponential Phan‐Thien/Tanner form. Simulations are conducted for these industrial problems through distributed parallel computation, using a semi‐implicit time‐stepping Taylor‐Galerkin/pressure‐correction algorithm. On typical field results and by comparing short‐against full‐die pressure‐tooling solutions, shear‐rates are observed to increase ten fold, while strain rates increase one hundred times. Tube‐tooling shear and extension‐rates are one quarter of those for pressure‐tooling. These findings across design options, have considerable bearing on the appropriateness of choice for the respective process involved. Parallel finite element results are generated on a homogeneous network of Intel‐chip workstations, running PVM (Parallel Vitual Machine) protocol over a Solaris operating system. Parallel timings yield practically ideal linear speed‐up over the set number of processors.

Additive manufacturing technology significantly simplifies the production of complex three-dimensional (3 D) parts directly from the computer-aided design (CAD) model. Although additive manufacturing (AM) processes have unexampled flexibility, they still have restrictions inhibiting engineers to easily generate some specific geometric shapes, easily. Some of these problems pertain to the consumption of materials as supports, the inferior surface finish of some surfaces with certain angles, etc. One of the approaches to overcome these problems is designing by segmentation.

The proposed methodology consists of two steps: (1) segmentation of the 3 D model and (2) exploring the best orientation for each segment. In the first step, engineers consider the possible number of segments and the connection method of segments. In this paper, a series of segments, called a segmentation pattern (SP), is obtained by the recognition of features and separating them automatically (or manually when needed) with one or more appropriate planes. In the second step, the best fabrication orientation should be chosen. The criteria for choosing the best SP and OPs are minimizing the support volume, building time (directly affected by segments’ height in layer-wise AM processes) and surface roughness. Both steps are performed automatically (or manually when needed) by the algorithm created based on principles of particle swarm optimization (PSO) algorithm using Visual C#.

Experimental tests show that the segmentation design improves AM processes from the aspects of building time, material consumption and the surface quality. Segmentation design empowers users of AM technologies to reduce consumption of material by decreasing the support structures, to decrease the time of building by lowering the segments height and to decrease the surface roughness.

This paper presents an original approach in efficiency improvement of AM technologies, thus bringing the AM one step closer to maturity.

An algorithm is described for the incremental solution of elastic—plastic finite element analysis using a piecewise holonomic constitutive law based on a von Mises yield condition. The holonomic assumption effectively converts each incremental problem into a non‐linear elastic—plastic problem. The algorithm is iterative, substituting the non‐linear strain potential by a quadratic potential at each iteration, and convergence is proved. The algorithm has been implemented into a finite element program as a series of secant modulus approximations, and results for a variety of problems are given. The rate of convergence is fairly slow, but the algorithm can be very easily programmed as an extension of an elastic program, and may have value as an independent method of determining incremental elastic—plastic solutions.

In this paper, we examine the influence of the third invariant in computational plasticity. For this purpose we consider the extended Leon model, an elasto‐plastic model for concrete materials which accounts for the difference of shear strength in triaxial compression and triaxial extension. Consequently, the deviatoric trace of the loading surface is no longer circular like in von Mises and Drucker‐Prager plasticity. In the limit it approaches the triangular shape of the Rankine condition of maximum direct stress. Thereby, elliptic functions describe the out‐of‐roundness of the circular trace in terms of C¹‐continuous functions of the Lode angle. The algorithmic aspects of the third invariant considerably complicate the computational implementation since the radial return method of J₂‐plasticity does no longer maintain normality leading to loss of deviatoric associativity. The paper will focus on the computational issues near the three regions with high curvature at the compressive meridians with special attention on the lack of convergence of the plastic return algorithm and its slow rate of convergence in these regions. The algorithmic discussion at the constitutive level will be augmented by the axial plane‐strain compression test in order to illustrate the effect of the third invariant at the structural level of finite element analysis.

Modern CAD systems facilitate the creation of any surface geometry imaginable, and complex surfaces for free-form grid shells are often represented by a set of Non-Uniform Rational B-Splines surface patches. But it remains an intractable issue how to generate high-quality grids on complex surfaces efficiently. To solve this issue, an automatic triangular mesh generation method is presented, based on bubble dynamics simulation and a modified Delaunay method.

A moderate amount of points are first distributed on a given surface. Next, by regarding the points as elastic bubbles with the same size and introducing the forces acting on bubbles, the motion control equations of bubbles are established. The equilibrium state of the bubble system is found by Verlet algorithm. Then, the Voronoi diagram on the surface is obtained by calculating the intersection between the surface and the three-dimensional (3D) Voronoi diagram of the centers of bubbles. Finally, a triangular mesh, Delaunay triangulation on the surface, is determined based on the dual change of the Voronoi diagram.

This method generates meshes on the surface directly, unlike mapping-based methods, avoiding the mapping distortion. Examples are given to demonstrate the successful execution of this method. The result also illustrates that this method is applicable to various surfaces in high automation level and resultant meshes are highly uniform and well-shaped.

Thus, this method provides the convenience for the geometry design of complex free-form grid structure.

Gives introductory remarks about chapter 1 of this group of 31 papers, from ISEF 1999 Proceedings, in the methodologies for field analysis, in the electromagnetic community. Observes that computer package implementation theory contributes to clarification. Discusses the areas covered by some of the papers ‐ such as artificial intelligence using fuzzy logic. Includes applications such as permanent magnets and looks at eddy current problems. States the finite element method is currently the most popular method used for field computation. Closes by pointing out the amalgam of topics.