An assessment of a parallel, finite element method for three‐dimensional, moving‐boundary flows driven by capillarity for simulation of viscous sintering

A parallel, finite element method is presented for the computation of three-dimensional, free-surface flows where surface tension effects are significant. The method employs an unstructured tetrahedral mesh, a front-tracking arbitrary Lagrangian–Eulerian formulation, and fully implicit time integration. Interior mesh motion is accomplished via pseudo-solid mesh deformation. Surface tension effects are incorporated directly into the momentum equation boundary conditions using surface identities that circumvent the need to compute second derivatives of the surface shape, resulting in a robust representation of capillary phenomena. Sample results are shown for the viscous sintering of glassy ceramic particles. The most serious performance issue is error arising from mesh distortion when boundary motion is significant. This effect can be severe enough to stop the calculations; some simple strategies for improving performance are tested. Copyright © 2001 John Wiley & Sons, Ltd.

[1]  Howard A. Stone,et al.  Dynamics of Drop Deformation and Breakup in Viscous Fluids , 1994 .

[2]  Jeffrey J. Derby,et al.  Massively parallel finite element computations of three-dimensional, time-dependent, incompressible flows in materials processing systems , 1994 .

[3]  Youcef Saad,et al.  Highly Parallel Preconditioners for General Sparse Matrices , 1994 .

[4]  Anthony T. Patera,et al.  Variational formulation of three‐dimensional viscous free‐surface flows: Natural imposition of surface tension boundary conditions , 1991 .

[5]  Yousef Saad,et al.  High-order ILU preconditioners for CFD problems , 2000 .

[6]  Andrew Johnson Mesh generation and update strategies for parallel computation of flow problems with moving boundaries and interfaces , 1995 .

[7]  John N. Shadid,et al.  A Comparison of Preconditioned Nonsymmetric Krylov Methods on a Large-Scale MIMD Machine , 1994, SIAM J. Sci. Comput..

[8]  Kenneth J. Ruschak,et al.  A method for incorporating free boundaries with surface tension in finite element fluid‐flow simulators , 1980 .

[9]  T. Hughes,et al.  A new finite element formulation for computational fluid dynamics: V. Circumventing the Babuscka-Brezzi condition: A stable Petrov-Galerkin formulation of , 1986 .

[10]  Thomas J. R. Hughes,et al.  The Stokes problem with various well-posed boundary conditions - Symmetric formulations that converge for all velocity/pressure spaces , 1987 .

[11]  Jeffrey J. Derby,et al.  Finite-element methods for analysis of the dynamics and control of Czochralski crystal growth , 1987 .

[12]  G. V. D. Vorst,et al.  Integral formulation to simulate the viscous sintering of a two-dimensional lattice of periodic unit cells , 1996 .

[13]  J. Derby,et al.  Theoretical analysis and design considerations for float-zone refinement of electronic grade silicon sheets , 1995 .

[14]  Pieter Wesseling,et al.  Vertex-centered and cell-centered multigrid for interface problems , 1992 .

[15]  Anthony T. Patera,et al.  A Legendre spectral element method for simulation of unsteady incompressible viscous free-surface flows , 1990 .

[16]  P. A. Sackinger,et al.  A finite element method for free surface flows of incompressible fluids in three dimensions. Part I. Boundary fitted mesh motion , 2000 .

[17]  Andrew Yeckel,et al.  Parallel Computation of Incompressible Flows in Materials Processing: Numerical Experiments in Diagonal Preconditioning , 1997, Parallel Comput..

[18]  J. Derby,et al.  Viscous Sintering of Spherical Particles via Finite Element Analysis , 1995 .

[19]  J. Derby,et al.  Analysis of capillary-driven viscous flows during the sintering of ceramic powders , 1994 .

[20]  C. Pozrikidis,et al.  The deformation of a liquid film flowing down an inclined plane wall over a small particle arrested on the wall , 1991 .

[21]  Tayfan E. Tezduyar,et al.  Stabilized Finite Element Formulations for Incompressible Flow Computations , 1991 .

[22]  C. W. Gear,et al.  Numerical initial value problem~ in ordinary differential eqttations , 1971 .

[23]  Rekha Ranjana Rao,et al.  A Newton-Raphson Pseudo-Solid Domain Mapping Technique for Free and Moving Boundary Problems , 1996 .

[24]  Tayfun E. Tezduyar,et al.  3D Simulation of fluid-particle interactions with the number of particles reaching 100 , 1997 .

[25]  E. J. Hinch,et al.  Numerical simulation of a concentrated emulsion in shear flow , 1996, Journal of Fluid Mechanics.

[26]  P. Gresho,et al.  An integrated process model for the growth of oxide crystals by the Czochralski method , 1989 .

[27]  R. Skalak,et al.  Motion and deformation of liquid drops, and the rheology of dilute emulsions in simple shear flow , 1994 .

[28]  Y. Saad,et al.  GMRES: a generalized minimal residual algorithm for solving nonsymmetric linear systems , 1986 .

[29]  Bruce Caswell,et al.  The solution of viscous incompressible jet and free-surface flows using finite-element methods , 1974, Journal of Fluid Mechanics.

[30]  Daniel R. Lynch,et al.  Continuously deforming finite elements for the solution of parabolic problems, with and without phase change , 1981 .

[31]  L. Scriven,et al.  Coating flow theory by finite element and asymptotic analysis of the navier-stokes system , 1984 .

[32]  Joe F. Thompson,et al.  Boundary-fitted coordinate systems for numerical solution of partial differential equations—A review , 1982 .

[33]  Lyle H. Ungar,et al.  Finite element methods for unsteady solidification problems arising in prediction of morphological structure , 1988, J. Sci. Comput..

[34]  J. Mackenzie,et al.  A Phenomenological Theory of Sintering , 1949 .

[35]  H. Kuiken Viscous sintering: the surface-tension-driven flow of a liquid form under the influence of curvature gradients at its surface , 1990, Journal of Fluid Mechanics.

[36]  L. Petzold Differential/Algebraic Equations are not ODE's , 1982 .

[37]  L. E. Scriven,et al.  Discretization of free surface flows and other moving boundary problems , 1992 .

[38]  P. A. Sackinger,et al.  A Finite Element Method for Free-Surface Flows of Incompressible Fluids in Three Dimensions, Part II: Dynamic Wetting Lines , 2000 .

[39]  G. Vorst Integral method for a two-dimensional Stokes flow with shrinking holes applied to viscous sintering , 1993, Journal of Fluid Mechanics.

[40]  V. Legat,et al.  Prediction of three‐dimensional general shape extrudates by an implicit iterative scheme , 1992 .

[41]  A. Nir,et al.  A simulation of surface tension driven coalescence , 1983 .

[42]  P. Dawson,et al.  Simulation of the Viscous Sintering of Two Particles , 1990 .

[43]  R. Mattheij,et al.  A boundary element solution for 2-dimensional viscous sintering , 1992 .

[44]  Jeffrey J. Derby,et al.  Massively parallel finite element analysis of coupled, incompressible flows: A benchmark computation of baroclinic annulus waves , 1995 .

[45]  Robert W. Hopper,et al.  Plane Stokes flow driven by capillarity on a free surface , 1990, Journal of Fluid Mechanics.

[46]  Steven A. Orszag,et al.  Surface-tension-driven Bénard convention at infinite Prandtl number , 1995, Journal of Fluid Mechanics.

[47]  Robert A. Brown,et al.  Theory of transport processes in single crystal growth from the melt , 1988 .

[48]  Tayfun E. Tezduyar,et al.  Mesh update strategies in parallel finite element computations of flow problems with moving boundaries and interfaces , 1994 .