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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 and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE 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 the last five years, and more than 1100 references are listed.

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.

A three‐dimensional, two‐phase computational model for simulating boiling‐enhanced mixed convection in free‐surface flows is presented. The associated constitutive models for the thermophysical and transport properties are described. A computational model incorporating the discrete‐element analysis was used to simulate the multi‐dimensional, two‐phase flow around a heated chip in a test tank filled with Freon‐(R113). Two and three‐dimensional simulations of both natural convection and nucleate boiling heat transfer regimes are presented. The velocity field, the temperature distribution, and the vapour concentration profiles are evaluated and discussed. The simulated heat fluxes are compared with the available experimental data. While the heat fluxes from the two‐dimensional simulation agree with the fluxes calculated for the three‐dimensional case, the flow in the tank is essentially three‐dimensional. The results show that there are secondary flows which cannot be captured by a two‐dimensional model. The heat flux in the boiling heat transfer regime is only about ten times larger than that in the natural convection regime due to the small vapour concentration in tank.

The non‐isothermal filling of a powder/binder mixture in metal injection moulding is simulated by the viscoplastic and the heat conduction finite element methods. Proposes a simplified three‐dimensional scheme for the moulding of products with a non‐uniform thickness distribution. The computing time for the simplified three‐dimensional scheme is of the same order as that for two‐dimensional problems. Deals with complex overlapping between the surfaces of the mixture, resulting from the occurrence of jetting during the moulding, by the use of a remeshing scheme. The material flow in metal injection moulding into a rectangular die with a linear thickness distribution is simulated. The jetting behaviour is remarkably influenced by the thickness distribution of the die.

The distinct element method as proposed by Cundall and Strack uses the computationally efficient, explicit, central difference time integration scheme. A limitation of this scheme is that it is only conditionally stable, so small time steps must be used. Some researchers have proposed using an implicit time integration scheme to avoid the stability issues arising from the explicit time integrator typically used in these simulations. However, these schemes are computationally expensive and can require a significant number of iterations to form the stiffness matrix that is compatible with the contact state at the end of each time step. In this paper, a new, simple approach for calculating the critical time increment in explicit discrete element simulations is proposed. Using this approach, it is shown that the critical time increment is a function of the current contact conditions. Considering both two‐ and three‐dimensional scenarios, the proposed refined estimates of the critical time step indicate that the earlier recommendations contained in the literature can be unconservative, in that they often overestimate the actual critical time step. A three‐dimensional simulation of a problem with a known analytical solution illustrates the potential for erroneous results to be obtained from discrete element simulations, if the time‐increment exceeds the critical time step for stable analysis.

Describes a set of numerical techniques which implement the rate‐dependent multi‐mechanism deformation (M‐D) constitutive model for rock salt in a finite element code for use in three‐dimensional, finite strain simulations of creep closure in deeply buried salt excavations. Presents essential details of the numerical implementation. The constitutive model is exercised in a three‐dimensional closure simulation of a large underground field experiment. Compares results from the simulation against actual closure measurements taken from the experiment.

The purpose of this paper is to quantify the relative importance of the multiphase model for the simulation of a gas bubble impacted by a normal shock wave in water. Both the free-field case and the collapse near a wall are investigated. Simulations are performed on both two- and three-dimensional configurations. The main phenomena involved in the bubble collapse are illustrated. A focus on the maximum pressure reached during the collapse is proposed.

Simulations are performed using an inviscid compressible homogeneous solver based on different systems of equations. It consists in solving different mixture or phasic conservation laws and a transport-equation for the gas volume fraction. Three-dimensional configurations are considered for which an efficient massively parallel strategy was developed. The code is based on a finite volume discretization for which numerical fluxes are computed with a Harten, Lax, Van Leer, Contact (HLLC) scheme.

The comparison of three multiphase models is proposed. It is shown that a simple four-equation model is well-suited to simulate such strong shock-bubble interaction. The three-dimensional collapse near a wall is investigated. It is shown that the intensity of pressure peaks on the wall is drastically increased (more than 200 per cent) in comparison with the cylindrical case.

The study of bubble collapse is a key point to understand the physical mechanism involved in cavitation erosion. The bubble collapse close to the wall has been addressed as the fundamental mechanism producing damage. Its general behavior is characterized by the formation of a water jet that penetrates through the bubble and the generation of a blast wave during the induced collapse. Both the jet and the blast wave are possible damaging mechanisms. However, the high-speed dynamics, the small spatio-temporal scales and the complicated physics involved in these processes make any theoretical and experimental approach a challenge.

Cavitation erosion is a major problem for hydraulic and marine applications. It is a limiting point for the conception and design of such components.

Such a comparison of multiphase models in the case of a strong shock-induced bubble collapse is clearly original. Usually models are tested separately leading to a large dispersion of results. Moreover, simulations of a three-dimensional bubble collapse are scarce in the literature using such fine grids.

The purpose of this paper is to study the influence of the processing parameters of diamond wire sawing on surface morphology and roughness.

First, a wire saw cutting model is established to determine the positional relationship between a wire saw and the machined surface of the workpiece, and the abrasive grain cutting trajectory is generated. Through the data processing of the cutting trajectory, the simulation of the three-dimensional surface topography of the slice and the calculation of the surface roughness are realized by using the GUI programming of MATLAB. Finally, different surface roughness values are obtained by changing the machining parameters (saw wire speed and workpiece feed speed).

The conclusion is that the surface roughness of the slice is larger when the feed speed is higher and smaller when the linear speed is higher.

Diamond wire saw cutting is the first process of chip processing, and its efficiency and quality have an important impact on subsequent processing. This paper will focus on the influence of the sawing wire cutting processing parameters (sawing wire speed and workpiece feed speed) on the surface roughness to optimize the processing parameters and obtain smaller surface roughness values. Through MATLAB three-dimensional simulation, the surface morphology can be observed more intuitively, which provides a theoretical basis for improving the processing quality.

The purpose of this paper is to investigate a model for convection induced by the selective absorption of radiation in a fluid layer. The concentration based internal heat source is modelled quadratically. Both linear instability and global nonlinear energy stability analyses are tested using three dimensional simulations. The results show that the linear threshold accurately predicts on the onset of instability in the basic steady state. However, the required time to arrive at the steady state increases significantly as the Rayleigh number tends to the linear threshold.

The author introduce the stability analysis of the problem of convection induced by absorption of radiation in fluid layer, then the author select a situations which have very big subcritical region. Then, the author develop a three dimensions simulation for the problem. To do this, first, the author transform the problem to velocity – vorticity formulation, then the author use a second order finite difference schemes. The author use implicit and explicit schemes to enforce the free divergence equation. The size of the Box is evaluated according to the normal modes representation. Moreover, the author adopt the periodic boundary conditions for velocity and temperature in the $x, y$ dimensions.

This paper explores a model for convection induced by the selective absorption of radiation in a fluid layer. The results demonstrate that the linear instability thresholds accurately predict the onset of instability. A three-dimensional numerical approach is adopted.

As the author believe, this paper is one of the first studies which deal with study of stability of convection using a three dimensional simulation. When the difference between the linear and nonlinear thresholds is very large, the comparison between these thresholds is very interesting and useful.

Studies of the three-dimensional flow characteristics during hydrofoil cavitation have shown that the side walls strongly affect the flow field around the hydrofoil. The purpose of this paper is to analyze the side wall effect for three-dimensional non-cavitating flows around a hydrofoil.

A three-dimensional non-cavitating flow field around a hydrofoil is analyzed for different attack angles using the RNG turbulence model and large eddy simulations (LES). The effect of the hydrofoil span was analyzed using LES simulations for various spans.

The lift coefficient, drag coefficient and pressure coefficient on the suction side are compared with experimental values. The results from the LES model (Smagorinsky-Lilly subgrid-scale model) agree better with the experimental data than those from the RNG turbulence model.

This paper shows that the flow around the hydrofoil has significant three-dimensional characteristics due to the side wall. For wide hydrofoils, the wall vortex region becomes essentially stable, and the width of the span has little effect on the middle region.