Multi-physics modelling for design optimization and manufacturing on high-performance parallel systems

An overview of the design and implementation of a software environment for the computational meddling of engineering processes is described, where the coupling amongst phenomena is strong. It is asserted that such a framework is necessary because of the numerical consistency and minimal data exchange required to enable such multi-physics calculations to be made effectively and in a practical time frame. The object based software framework uses 3D finite volume techniques on an unstructured mesh that facilitates free surface flows, heat transfer with phase change and non-linear solid mechanics. High parallel efficiencies are demonstrated and applications of the software framework to a range of problems with various degrees of coupling amongst the physical phenomena are highlighted. Particularly, in the context of shape casting, it is demonstrated how that simulation of the interactions is necessary to predict the defects of key interest to the target manufacturing sectors.