This paper presents practical capabilities of a system for ceramic mould quality forecasting implemented in an industrial plant (foundry). The main assumption of the developed solution is the possibility of eliminating a faulty mould from a production line just before the casting operation. It allows relative savings to be achieved, and faulty moulds, and thus faulty castings occurrence in the production cycle to be minimized. The numerical computing module (the DEFFEM 3D package), based on the smoothed particle hydrodynamics (SPH) is one of key solutions of the system implemented. Due to very long computing times, the developed numerical module cannot be effectively used to carry out multi-variant simulations of mould filling and solidification of castings. To utilize the benefits from application of the CUDA architecture to improve the computing effectiveness, the most time consuming procedure of looking for neighbours was parallelized (cell-linked list method). The study is complemented by examples of results of performance tests and their analysis.

This article presents a sequential model of the heating-remelting-cooling of steel samples based on the finite element method (FEM) and the smoothed particle hydrodynamics (SPH). The numerical implementation of the developed solution was completed as part of the original DEFFEM 3D package, being developed for over ten years, and is a dedicated tool to aid physical simulations performed with modern Gleeble thermo-mechanical simulators. Using the developed DEFFEM 3D software to aid physical simulations allows the number of costly tests to be minimized, and additional process information to be obtained, e.g. achieved local cooling rates at any point in the sample tested volume, or characteristics of temperature changes. The study was complemented by examples of simulation and experimental test results, indicating that the adopted model assumptions were correct. The developed solution is the basis for the development of DEFFEM 3D software aimed at developing a comprehensive numerical model allows the simulation of deformation of steel in semi solid state.

This work outlines a unified multi-threaded, multi-scale High Performance Computing (HPC) approach for the direct numerical simulation of Fluid-Solid Interaction (FSI) problems. The simulation algorithm relies on the extended Smoothed Particle Hydrodynamics (XSPH) method, which approaches the fluid flow in a Lagrangian framework consistent with the Lagrangian tracking of the solid phase. A general 3D rigid body dynamics and an Absolute Nodal Coordinate Formulation (ANCF) are implemented to model rigid and flexible multibody dynamics. The twoway coupling of the fluid and solid phases is supported through use of Boundary Condition Enforcing (BCE) markers that capture the fluid-solid coupling forces by enforcing a no-slip boundary condition. The solid-solid short range interaction, which has a crucial impact on the small-scale behavior of fluid-solid mixtures, is resolved via a lubrication force model. The collective system states are integrated in time using an explicit, multi-rate scheme. To alleviate the heavy computational load, the overall algorithm leverages parallel computing on Graphics Processing Unit (GPU) cards. Performance and scaling analysis are provided for simulations scenarios involving one or multiple phases with up to tens of thousands of solid objects. The software implementation of the approach, called Chrono::Fluid, is part of the Chrono project and available as an open-source software.

The paper presents the results of experimental-numerical tests of firing at aluminum composite materials. The test materials were manufactured by pressure infiltration of porous ceramic preforms made of -Al2O3 particles in the amount of 30% and 40% by volume. The EN AW-7075 alloy was chosen as the material matrix, and the steel 7.62×39 mm (M 43) FMJ (Full Metal Jacket) intermediate ammunition was selected for firing. In the result of the experiment, the samples were perforated with a clear difference in the muzzle diameter. The projectile with fragments caused damage to up to three reference plates placed behind the samples (witness plates) in composites with 40% of particles by volume. The mechanics of crack propagation during ballistic impacts of the projectile was characterized based on microstructure studies. Then, using numerical analysis of impact load, the examination of composite materials puncture in the ABAQUS environment was carried out. The Finite Element Method (FEM) was employed for the discretization of geometric models using Hex elements. The Johnson-Cook constitutive model describing the relationship between stress and strain in metal-ceramic composites was applied for the analyses. Numerical models were then subjected to numerical verification using smoothed particle hydrodynamics (SPH). Based on the obtained results, it was found that the hybrid FEM/SPH method correlates significantly with the experimental results.

Smoothed Particle Hydrodynamics (SPH) is a Lagrangian formula-based non-grid computational method for simulating fluid flows, solid deformation, and fluid structured systems. SPH is a method widely applied in many fields of science and engineering, especially in the field of materials science. It solves complex physical deformation and flow problems. This paper provides a basic overview of the application of the SPH method in metal processing. This is a very useful simulation method for reconstructing flow patterns, solidification, and predicting defects, limitations, or material destruction that occur during deformation. The main purpose of this review article is to give readers better understanding of the SPH method and show its strengths and weaknesses. Studying and promoting the advantages and overcoming the shortcomings of the SPH method will help making great strides in simulation modeling techniques. It can be effectively applied in training as well as for industrial purposes.