Two-way coupling of thin shell finite element magnetic models via an iterative subproblem method

Purpose The purpose of this paper is to deal with the correction of the inaccuracies near edges and corners arising from thin shell models by means of an iterative finite element subproblem method. Classical thin shell approximations of conducting and/or magnetic regions replace the thin regions with impedance-type transmission conditions across surfaces, which introduce errors in the computation of the field distribution and Joule losses near edges and corners. Design/methodology/approach In the proposed approach local corrections around edges and corners are coupled to the thin shell models in an iterative procedure (each subproblem being influenced by the others), allowing to combine the efficiency of the thin shell approach with the accuracy of the full modelling of edge and corner effects. Findings The method is based on a thin shell solution in a complete problem, where conductive thin regions have been extracted and replaced by surfaces but strongly neglect errors on computation of the field distribution and Joule losses near edges and corners. Research limitations/implications This model is only limited to thin shell models by means of an iterative finite element subproblem method. Originality/value The developed method is considered to couple subproblems in two-way coupling correction, where each solution is influenced by all the others. This means that an iterative procedure between the subproblems must be required to obtain an accurate (convergence) solution that defines as a series of corrections.

Edge and corner effects in selective laser melting of IN 625 alloy

Experimental investigations on top surface of prismatic specimens, manufactured by Selective Laser Melting of IN 625 alloy, were carried out in order to assess the influence of laser power and scanning speed on edge and corner effects. Since the melt-pool behaviour is strongly influenced by the process parameters, all specimens were manufactured with no contour using the same layer thickness, hatch distance and scanning strategy at different levels of laser powers and scanning speeds. 3D laser surface scanning was performed in order to measure surface changes. The experimental results have revealed that melt-pool behaviour during solidification generates elevated ridges on both specimen sides and corners that are strongly influenced by the energy input. The edge ridges width increases with increasing the laser power and decrease with increasing the scanning speed, the rising of corners being much more pronounced. On the contrary, at constant laser power and variable scanning speeds the edge and corner ridges decrease.

Corner effects for oblique shock wave/turbulent boundary layer interactions in rectangular channels

In a rectangular cross-section wind tunnel, a separated oblique shock reflection is set to interact with the turbulent boundary layer (oblique shock wave/turbulent boundary layer interaction (SBLI)) both on the bottom wall and in the corners formed by the intersection of the floor with the sidewalls. To examine how corner separations can affect the ‘quasi-two-dimensional’ main interaction and by what mechanisms this is achieved, an experimental investigation has been conducted. This examines how modifications to the corner separation affect an $M=2.5$ oblique shock reflection. The nature of the flow field is studied using flow visualisation, pressure-sensitive paint and laser Doppler anemometry. The results show that the size and shape of central separation vary considerably when the onset and magnitude of corner separation changes. The primary mechanism explaining the coupling between these separated regions appears to be the generation of compression waves and expansion fans as a result of the displacement effect of the corner separation. This is shown to modify the three-dimensional shock structure and alter the adverse pressure gradient experienced by the tunnel floor boundary layer. It is suggested that a typical oblique SBLI in rectangular channels features several zones depending on the relative position of the corner waves and the main interaction domain. In particular, it has been shown that the position of the corner ‘shock’ crossing point, found by approximating the corner compression waves by a straight line, is a critical factor determining the main separation size and shape. Thus, corner effects can substantially modify the central separation. This can cause significant growth or contraction of the separation length measured along the symmetry line from the nominally two-dimensional baseline value, giving a fivefold increase from the smallest to the largest observed value. Moreover, the shape and flow topology of the centreline separation bubble is also considerably changed by varying corner effects.