A Lagrangian-Eulerian simulation method for viscoelastic flows applied to adhesive joining
Doktorsavhandling, 2022

Viscoelastic flows are important for many industrial processes, such as adhesive joining, polymer extrusion and additive manufacturing. Numerical simulations enable virtual evaluation and product realization, which can support the design phase and reduce the amount of costly physical testing. However, such applications are challenging to simulate. Thus, efficient, robust and user-friendly simulation methods are needed.

In this thesis, a Lagrangian--Eulerian simulation framework for viscoelastic flow is presented. The constitutive equation is solved at Lagrangian nodes, convected by the flow, while the momentum and continuity equations are discretized with the finite volume method. The volume of fluid method is used to model free-surface flow, with an injection model for extrusion along arbitrary nozzle paths. The solver combines an automatic and adaptive octree background grid with implicit immersed boundary conditions. In contrast to boundary-conformed mesh techniques, the framework handles arbitrary geometry and moving objects efficiently. Furthermore, novel coupling methods between the Lagrangian and Eulerian solutions as well as unique treatment of the Lagrangian stresses at the fluid-fluid interface are developed. Consequently, the resulting method can simulate the complex flows associated with the intended applications, without the need for advanced stabilization techniques.

The framework is validated for a variety of flows, including relevant benchmarks as well as industrial adhesive joining applications. The latter includes robot-carried adhesive extrusion onto a car fender as well as a hemming application. The results agree with the available experimental data. As such, the research presented in this thesis can contribute to enable virtual process development for joining applications.

computational fluid dynamics

immersed boundary methods

volume of fluid

viscoelastic flow

adhesive joining

Virtual Development Laboratory, Chalmers Tvärgata 4C, Göteborg
Opponent: Dr Oliver Harlen, University of Leeds, UK. Password for Zoom-link: 696600


Simon Ingelsten

Chalmers, Industri- och materialvetenskap, Konstruktionsmaterial

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Ingelsten, S. Mark, A. Kádár, R. Edelvik, F. Simulation of viscoelastic adhesive joining processes

Viscoelastic fluids are complex materials which exhibit the behaviors of both viscous liquids and elastic solid materials. Such materials appear in important industrial processes, such as additive manufacturing, automotive sealing, polymer extrusion and adhesive joining applications. Computer simulations can enable process verification and optimization in a virtual environment. This can reduce the need for time-consuming physical testing and aid the development of sustainable manufacturing processes. However, many of the processes have complex features which make them challenging to simulate. New computational algorithms are therefore called for, which enable simulation of these applications and which can predict the outcome in an efficient, robust and user-friendly manner.

In this thesis, a new simulation method for viscoelastic fluid flow is presented. While the computational algorithm is generally designed, particular focus is aimed at the viscoelastic flows in adhesive joining applications. The simulation framework is able to simulate for example adhesive extrusion along an industrial robot path, parts assembly and hemming joining. As a result, the research in this thesis can contribute to enable virtual tools for optimization and verification of adhesive joining applications using computer simulations.





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Doktorsavhandlingar vid Chalmers tekniska högskola. Ny serie: 5108



Virtual Development Laboratory, Chalmers Tvärgata 4C, Göteborg


Opponent: Dr Oliver Harlen, University of Leeds, UK. Password for Zoom-link: 696600

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