Solving conjugate heat transfer design problems is relevant for various engineering applications requiring efficient thermal management. Heat exchange between fluid and solid can be enhanced by optimizing the system layout and the shape of the flow channels. As heat is transferred at fluid/solid interfaces, it is crucial to accurately resolve the geometry and the physics responses across these interfaces. To address this challenge, this work investigates for the first time the use of an eXtended Finite Element Method (XFEM) approach to predict the physical responses of conjugate heat transfer problems considering turbulent flow. This analysis approach is integrated into a level set-based optimization framework. The design domain is immersed into a background mesh and the geometry of fluid/solid interfaces is defined implicitly by one or multiple level set functions. The level set functions are discretized by higher-order B-splines. The flow is predicted by the Reynolds Averaged Navier–Stokes equations. Turbulence is described by the Spalart–Allmaras model and the thermal energy transport by an advection–diffusion model. Finite element approximations are augmented by a generalized Heaviside enrichment strategy with the state fields being approximated by linear basis functions. Boundary and interface conditions are enforced weakly with Nitsche’s method, and the face-oriented ghost stabilization is used to mitigate numerical instabilities associated with the emergence of small integration subdomains. The proposed XFEM approach for turbulent conjugate heat transfer is validated against benchmark problems. Optimization problems are solved by gradient-based algorithms and the required sensitivity analysis is performed by the adjoint method. The proposed framework is illustrated with the design of turbulent heat exchangers in two dimensions. The optimization results show that, by tuning the shape of the fluid/solid interface to generate turbulence within the heat exchanger, the transfer of thermal energy can be increased.

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Multi-material problems often exhibit complex geometries along with physical responses presenting large spatial gradients or discontinuities. In these cases, providing high-quality body-fitted finite element analysis meshes and obtaining accurate solutions remain challenging. Immersed boundary techniques provide elegant solutions for such problems. Enrichment methods alleviate the need for generating conforming analysis grids by capturing discontinuities within mesh elements. Additionally, increased accuracy of physical responses and geometry description can be achieved with higher-order approximation bases. In particular, using B-splines has become popular with the development of IsoGeometric Analysis. In this work, an eXtended IsoGeometric Analysis (XIGA) approach is proposed for multi-material problems. The computational domain geometry is described implicitly by level set functions. A novel generalized Heaviside enrichment strategy is employed to accommodate an arbitrary number of materials without artificially stiffening the physical response. Higher-order B-spline functions are used for both geometry representation and analysis. Boundary and interface conditions are enforced weakly via Nitsche’s method, and a new face-oriented ghost stabilization methodology is used to mitigate numerical instabilities arising from small material integration subdomains. Two- and three-dimensional heat transfer and elasticity problems are solved to validate the approach. Numerical studies provide insight into the ability to handle multiple materials considering sharp-edged and curved interfaces, as well as the impact of higher-order bases and stabilization on the solution accuracy and conditioning.

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Ill-conditioning of the system matrix is a well-known complication in immersed finite element methods and trimmed isogeometric analysis. Elements with small intersections with the physical domain yield problematic eigenvalues in the system matrix, which generally degrades efficiency and robustness of iterative solvers. In this contribution we investigate the spectral properties of immersed finite element systems treated by Schwarz-type methods, to establish the suitability of these as smoothers in a multigrid method. Based on this investigation we develop a geometric multigrid preconditioner for immersed finite element methods, which provides mesh-independent and cut-element-independent convergence rates. This preconditioning technique is applicable to higher-order discretizations, and enables solving large-scale immersed systems at a computational cost that scales linearly with the number of degrees of freedom. The performance of the preconditioner is demonstrated for conventional Lagrange basis functions and for isogeometric discretizations with both uniform B-splines and locally refined approximations based on truncated hierarchical B-splines.

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In this paper, we address a newly discovered local instability observed in geometrically nonlinear analysis using the Internal Element Connectivity Parameterization (I-ECP) approach. I-ECP offers advantages in topology optimization of nonlinear elastic structures compared to conventional material scaling approaches (e.g. SIMP), including more robustness against excessive deformations. However, under certain conditions, we observe local instabilities in low-density areas using I-ECP as well. These instabilities can result in analysis failure and premature termination of the topology optimization process. We report on this finding and present a small numerical example exhibiting the undesired behavior. Furthermore, we provide insight into its origin on a fundamental level based on an I-ECP truss as well as using the general I-ECP governing equations. In conclusion, when sufficient support of surrounding elements is lacking, highly compressed I-ECP patches can trigger a buckling mode on system level. Our analysis reveals that the element-link arrangement employed in I-ECP results in a magnification of negative eigenvalues, which promotes the instability. In addition to an investigation of this phenomena, we provide various directions for stabilization. Keywords: Topology optimization, Internal Element Connectivity Parameterization, geometrical nonlinearity, material nonlinearity, instability.@en