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Federico Mazzanti's project introduces a novel family of vertex-centred finite volume solvers for modeling both small-strain and large-strain elastoplasticity. Developed within the OpenFOAM environment, these solvers address the efficiency limitations of traditional cell-centred segregated solvers, especially in high-aspect-ratio geometries. This work offers a robust framework for advancing solid mechanics simulations, with the potential to optimise manufacturing processes and ultimately reduce operational costs across industries.

In the realm of solid mechanics, numerical simulations are crucial for optimising manufacturing processes, reducing costs and minimising material waste. However, current simulation tools often struggle with efficiency, particularly when dealing with high-aspect-ratio geometries. Traditional cell-centred segregated solvers, while widely used, are limited by their computational inefficiency, particularly when there is a strong inter-component coupling.

To address these challenges, Federico's project develops a new family of vertex-centred, block-coupled finite volume solvers within the OpenFOAM framework, specifically designed to handle both small-strain and large-strain elastoplastic behaviour in solids. By adopting a vertex-centred approach, these solvers leverage a dual mesh that offers a more efficient application of boundary conditions. They also allow for direct coupling of pressure and displacement, significantly mitigating pressure oscillations that are common in simulations of nearly incompressible materials.

The block-coupled nature of these solvers means that the system solves all governing equations simultaneously, rather than sequentially, achieving faster convergence and higher computational efficiency. Additionally, extensive validation and benchmarking against classic problems in solid mechanics demonstrate that these solvers significantly outperform traditional segregated methods in terms of computational efficiency. This work ultimately establishes a comprehensive and adaptable framework for the finite volume method in elastoplasticity, with potential applications across various engineering fields, promising a valuable toolset for more accurate and cost-effective manufacturing simulations.

As I delved into the development of these new finite volume solvers, it became clear how impactful this work could be for advancing computational efficiency in solid mechanics. Seeing firsthand how our vertex-centred approach streamlined high-aspect-ratio problems was incredibly rewarding. The real turning point was when we tested the solver in scenarios that traditionally hindered performance, and it consistently outpaced the existing methods. For an engineer, there’s nothing quite like watching a concept translate into a robust, real-world application. Working in the OpenFOAM environment provided the flexibility needed to refine each component of the solver, from boundary conditions to coupling schemes, making this project feel as much an exercise in precision as in creativity. This experience strengthened my conviction that innovative approaches can push boundaries, enabling faster and more reliable simulations. I hope this work will be a valuable resource for industries looking to optimise manufacturing processes and reduce costs, while also inspiring others to innovate beyond conventional methods.

Federico Mazzanti

This project represents a significant leap forward in the field of computational solid mechanics, with direct implications for industries that rely on precise and efficient material simulations. The newly developed vertex-centred, block-coupled solvers within the OpenFOAM framework offer a way to perform elastoplastic simulations with higher accuracy and computational efficiency. For companies, this translates to faster design cycles, cost reductions and the ability to explore a broader range of design options without extensive physical testing. Optimised simulations can help manufacturers reduce waste by predicting the exact amount of material needed, which not only lowers production costs but also supports sustainability efforts.

On a broader level, the impact of these advancements reaches industries directly involved in shaping materials through processes like rolling and drawing, which are fundamental to manufacturing many of the products we use daily. These processes, widely used in industries like automotive, construction and consumer goods, rely heavily on accurate simulations to refine materials for specific applications, ensuring strength, durability and efficient material usage. By enabling more precise and efficient simulations of material behaviour during rolling and drawing, this project has the potential to enhance the ability of engineers to predict and control outcomes such as thickness, tensile strength and surface finish, which are essential for creating high-quality products. Additionally, by reducing the time and computational cost required to complete these simulations, the industry can bring products to market faster, enabling quicker adaptation to consumer needs and advances in safety.

This project underscores the potential for computational mechanics to drive innovation and efficiency across multiple fields. Ultimately, these advancements in solid mechanics simulation contribute to safer, more sustainable and cost-effective solutions in engineering and manufacturing, benefitting both industries and the consumers they serve.

Biography

Federico Mazzanti is a Ph.D. researcher in I-Form and is based in UCD working in the area of computational analysis for metal forming. He obtained his undergraduate First Class Honours degree in Science with Nanotechnology from Technological University Dublin in 2020 and then started his Ph.D. in computational mechanics soon after. His main research interests are in the areas of finite volume methods, metal forming and computational studies.
Since beginning his Ph.D., Federico Mazzanti has focused on implementing block-coupled finite volume methodologies for modelling small-strain and large-strain elastoplasticity in solid mechanics. His primary goal has been to enhance the computational efficiency of existing state-of-the-art finite volume methods, such as the cell-centred segregated method commonly used in industry, especially for high-aspect ratio problems. His work was presented at the 18th OpenFOAM Conference in Genoa, Italy, in 2023.