A Benchmark for Fluid-Structure Interaction in Hybrid Manufacturing: Coupled Eulerian-Lagrangian Simulation

Several hybrid manufacturing processes involve fluid-structure interaction (FSI), i.e. a bi-directional mechanical interaction between a deformable solid and a fluid flow. For example, FSI may occur during compression of a foam core in composite sandwich parts, during the deformation of an insert in an over-molding process, during the simultaneous forming and filling of novel fiber metal laminates, or during Liquid Compression Molding processes (WCM). Reliable process simulations are required to support engineering of such complex manufacturing processes. However, simulating such manufacturing processes is challenging due to the varying spatial domains and due to the deforming interface between fluid and solid phase. This work presents an FSI benchmark setup specifically for hybrid manufacturing in order to verify and evaluate several simulation approaches. The test allows for simultaneous deformation of a circular metal blank and cylindrical squeeze flow of a highly viscous fluid. Compression force, blank deformation and fluid flow front propagation are recorded during trials and compared to several numerical simulation approaches. This contribution highlights the results obtained with a Coupled Eulerian Langrangian approach. ... mehr
In this approach, the blank is modeled via conventional Lagrangian shell elements, which interact with partially filled fluid elements at a reconstructed surface. The deformation of fluid nodes is mapped back during each time step while the flow through fluid element faces is corrected such that the resulting fluid behavior is effectively Eulerian.