Numerical simulations of concrete processing: From standard formative casting to additive manufacturing

Abstract The concrete industry is facing new digital shaping processes that still have to be optimized and that require cement-based materials, for which fresh properties requirements are yet to be defined. In this paper, we first present the state of the art in the field of numerical simulations of concrete flow. We then focus on the literature on numerical simulations of extrusion-based additive manufacturing processes for concrete. Our review shows that the available numerical modelling tools are able to detect and predict various type of failures through the printing process, no matter if these happen at the scale of the nozzle, of one printed layer or of the entire object being printed. As they allow for a systematic evaluation of the influence of the entire range of material, geometric and process parameters, numerical modelling is a valid option to optimize both process and material.

[1]  Joel H. Ferziger,et al.  Computational methods for fluid dynamics , 1996 .

[2]  Jon Elvar Wallevik,et al.  Numerical simulation of fresh concrete flow: insight and challenges , 2019, RILEM Technical Letters.

[3]  Hiroshi Mori,et al.  FLOW SIMULATION OF FRESH CONCRETE CAST INTO WALL STRUCTURE BY VISCOPLASTIC DIVIDED SPACE ELEMENT METHOD , 1997 .

[4]  Jon Elvar Wallevik,et al.  Concrete mixing truck as a rheometer , 2020 .

[5]  Jon Elvar Wallevik,et al.  Minimizing end-effects in the coaxial cylinders viscometer : Viscoplastic flow inside the ConTec BML Viscometer 3 , 2008 .

[6]  Knut Krenzer,et al.  Simulation of fresh concrete flow using Discrete Element Method (DEM): theory and applications , 2014 .

[7]  Jon Elvar Wallevik,et al.  Rheology of Particle Suspensions: Fresh Concrete, Mortar and Cement Paste with Various Types of Lignosulfonates , 2003 .

[8]  J. Anderson,et al.  Computational fluid dynamics : the basics with applications , 1995 .

[9]  F. Toutlemonde,et al.  SCC casting prediction for the realization of prototype VHPC-precambered composite beams , 2007 .

[10]  Rjm Rob Wolfs,et al.  Structural failure during extrusion-based 3D printing processes , 2019, The International Journal of Advanced Manufacturing Technology.

[11]  Freek Bos,et al.  Hardened properties of 3D printed concrete: The influence of process parameters on interlayer adhesion , 2019, Cement and Concrete Research.

[12]  Nicolas Roussel,et al.  Correlation between Yield Stress and Slump: Comparison between Numerical Simulations and Concrete Rheometers Results , 2005 .

[13]  Henrik Stang,et al.  Simulation of the Test Method "L-Box" for Self-Compacting Concrete , 2004 .

[14]  U. Perego,et al.  Simulation of the flow of fresh cement suspensions by a Lagrangian finite element approach , 2010 .

[15]  Liberato Ferrara,et al.  Numerical simulations of concrete flow: A benchmark comparison , 2016 .

[16]  Henrik Stang,et al.  Free surface flow of a suspension of rigid particles in a non-Newtonian fluid: A lattice Boltzmann approach , 2012 .

[17]  Birol Kaya,et al.  Numerical Simulation of Two Dimensional Unsteady Flow By Total Variation Diminishing Scheme , 2016 .

[18]  Edin Berberović,et al.  Investigation of Free-surface Flow Associated with Drop Impact: Numerical Simulations and Theoretical Modeling , 2010 .

[19]  C. Hu,et al.  RHEOLOGIE DES BETONS FLUIDES , 1995 .

[20]  Pathmanathan Rajeev,et al.  Direct shear test for the assessment of rheological parameters of concrete for 3D printing applications , 2019, Materials and Structures.

[21]  Vincent Picandet,et al.  Prediction of lateral form pressure exerted by concrete at low casting rates , 2015 .

[22]  Nicolas Roussel,et al.  Rheological requirements for printable concretes , 2018, Cement and Concrete Research.

[23]  Amir M. Halabian,et al.  Simulation of concrete flow in V-funnel test and the proper range of viscosity and yield stress for SCC , 2014 .

[24]  Nicolas Roussel,et al.  Weak bond strength between successive layers in extrusion-based additive manufacturing: measurement and physical origin , 2019, Cement and Concrete Research.

[25]  Nicolas Roussel,et al.  A Physical Model for the Prediction of Lateral Stress Exerted by Self-Compacting Concrete on Formwork , 2005 .

[26]  Nicolas Roussel,et al.  Recent advances on yield stress and elasticity of fresh cement-based materials , 2019, Cement and Concrete Research.

[27]  P. Woodward,et al.  SLIC (Simple Line Interface Calculation) , 1976 .

[28]  Asj Akke Suiker,et al.  Mechanical performance of wall structures in 3D printing processes: Theory, design tools and experiments , 2018 .

[29]  David Bue Pedersen,et al.  Experimental validation of a numerical model for the strand shape in material extrusion additive manufacturing , 2018, Additive Manufacturing.

[30]  C. Fletcher.  Computational techniques for fluid dynamics , 1992 .

[31]  C. O’Sullivan.  Particulate Discrete Element Modelling: A Geomechanics Perspective , 2011 .

[32]  Birgit Meng,et al.  Flow of fresh concrete through steel bars: A porous medium analogy , 2011 .

[33]  O. Zikanov.  Essential Computational Fluid Dynamics , 2010 .

[34]  David Bue Pedersen,et al.  Motion planning and numerical simulation of material deposition at corners in extrusion additive manufacturing , 2019, Additive Manufacturing.

[35]  Ammar Yahia,et al.  Extension of the Reiner–Riwlin equation to determine modified Bingham parameters measured in coaxial cylinders rheometers , 2013 .

[36]  Hiroshi Mori,et al.  ANALYTICAL STUDY ON EFFECT OF VOLUME FRACTION OF COARSE AGGREGATE ON BINGHAM'S CONSTANTS OF FRESH CONCRETE , 1997 .

[37]  Celeste Viljoen,et al.  3D concrete printer parameter optimisation for high rate digital construction avoiding plastic collapse , 2020 .

[38]  Nicolas Roussel,et al.  Rheology of fresh concrete: from measurements to predictions of casting processes , 2007 .

[39]  Nicolas Roussel,et al.  “Fifty-cent rheometer” for yield stress measurements: From slump to spreading flow , 2005 .

[40]  Nicolas Roussel,et al.  The LCPC BOX: a cheap and simple technique for yield stress measurements of SCC , 2007 .

[41]  Nicolas Roussel,et al.  The origins of thixotropy of fresh cement pastes , 2012 .

[42]  Freek Bos,et al.  Correlation between destructive compression tests and non-destructive ultrasonic measurements on early age 3D printed concrete , 2018, Construction and Building Materials.

[43]  Damien Rangeard,et al.  Structural built-up of cement-based materials used for 3D-printing extrusion techniques , 2016 .

[44]  Lex Reiter,et al.  The role of early age structural build-up in digital fabrication with concrete , 2018, Cement and Concrete Research.

[45]  P. Español,et al.  Perspective: Dissipative particle dynamics. , 2016, The Journal of chemical physics.

[46]  Hiroshi Mori,et al.  Simulation methods for Fluidity of fresh concrete. , 1992 .

[47]  Falk K. Wittel,et al.  Evolution of strength and failure of SCC during early hydration , 2016, 1609.02293.

[48]  Freek Bos,et al.  Early age mechanical behaviour of 3D printed concrete: Numerical modelling and experimental testing , 2018 .

[49]  D. B. Pedersen,et al.  Modelling of Material Deposition in Big Area Additive Manufacturing and 3D Concrete Printing , 2019 .

[50]  Nicolas Roussel,et al.  A thixotropy model for fresh fluid concretes: Theory, validation and applications , 2006 .

[51]  Rüdiger Schwarze,et al.  Numerical simulation of a single rising bubble by VOF with surface compression , 2013 .

[52]  Bhushan Lal Karihaloo,et al.  Simulation of self-compacting concrete in an L-box using smooth particle hydrodynamics , 2017 .

[53]  Mahmud Ashrafizaadeh,et al.  A mesh-free lattice Boltzmann solver for flows in complex geometries , 2016 .

[54]  F. Durst,et al.  Comparison of volume-of-fluid methods for surface tension-dominant two-phase flows , 2006 .

[55]  C. W. Hirt,et al.  Volume of fluid (VOF) method for the dynamics of free boundaries , 1981 .

[56]  Krotil Stefan,et al.  CFD-Simulations in the Early Product Development , 2016 .

[57]  David Bue Pedersen,et al.  Numerical simulations of the mesostructure formation in material extrusion additive manufacturing , 2019, Additive Manufacturing.

[58]  Hans-Carsten Kühne,et al.  Flow of fresh concrete through reinforced elements: Experimental validation of the porous analogy numerical method , 2016 .

[59]  Nicos Martys,et al.  Study of a dissipative particle dynamics based approach for modeling suspensions , 2005 .

[60]  R. Deeb,et al.  3D modelling of the flow of self-compacting concrete with or without steel fibres. Part II: L-box test and the assessment of fibre reorientation during the flow , 2014 .

[61]  H. Rusche.  Computational fluid dynamics of dispersed two-phase flows at high phase fractions , 2003 .

[62]  Lars Thrane,et al.  Form Filling with Self-Compacting Concrete , 2007 .

[63]  Thierry Sedran,et al.  Validation of BTRHEOM, the new rheometer for soft-to-fluid concrete , 1996 .

[64]  Berend van Wachem,et al.  Volume of fluid methods for immiscible-fluid and free-surface flows , 2008 .

[65]  T.A.M. Salet,et al.  Triaxial compression testing on early age concrete for numerical analysis of 3D concrete printing , 2019, Cement and Concrete Composites.

[66]  Viktor Mechtcherine,et al.  Virtual Sliding Pipe Rheometer for estimating pumpability of concrete , 2018 .

[67]  Jiyuan Tu,et al.  Computational Fluid Dynamics: A Practical Approach , 2007 .

[68]  Frédéric Dufour,et al.  Computational modeling of concrete flow: General overview , 2007 .

[69]  Jesper Henri Hattel,et al.  Flow induced particle migration in fresh concrete: Theoretical frame, numerical simulations and experimental results on model fluids , 2012 .

[70]  Weeratunge Malalasekera,et al.  An introduction to computational fluid dynamics - the finite volume method , 2007 .

[71]  Jon Elvar Wallevik,et al.  Computational Segregation Analysis During Casting of SCC , 2019, RILEM Bookseries.