In this work we present a novel computational method for embedding arbitrary curved one-dimensional (1D) fibers into three-dimensional (3D) solid volumes, as e.g. in fiber-reinforced materials. The fibers are explicitly modeled with highly efficient 1D geometrically exact beam finite elements, based on various types of geometrically nonlinear beam theories. The surrounding solid volume is modeled with 3D continuum (solid) elements. An embedded mortar-type approach is employed to enforce the kinematic coupling constraints between the beam elements and solid elements on non-matching meshes. This allows for very flexible mesh generation and simple material modeling procedures in the solid, since it can be discretized without having to account for the reinforcements, while still being able to capture complex nonlinear effects due to the embedded fibers. Several numerical examples demonstrate the consistency, robustness and accuracy of the proposed method, as well as its applicability to rather complex fiber-reinforced structures of practical relevance.

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This work addresses research questions arising from the application of geometrically exact beam theory in the context of fluid-structure interaction (FSI). Geometrically exact beam theory has proven to be a computationally efficient way to model the behavior of slender structures while leading to rather well-posed problem descriptions. In particular, we propose a mixed-dimensional embedded finite element approach for the coupling of one-dimensional geometrically exact beam equations to a three-dimensional background fluid mesh, referred to as fluid–beam interaction (FBI) in analogy to the well-established notion of FSI. Here, the fluid is described by the incompressible isothermal Navier–Stokes equations for Newtonian fluids. In particular, we present algorithmic aspects regarding the solution of the resulting one-way coupling schemes and, through selected numerical examples, analyze their spatial convergence behavior as well as their suitability not only as stand-alone methods but also for an extension to a full two-way coupling scheme.

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The present article proposes a mortar-type finite element formulation for consistently embedding curved, slender beams into 3D solid volumes. Following the fundamental kinematic assumption of undeformable cross-section s, the beams are identified as 1D Cosserat continua with pointwise six (translational and rotational) degrees of freedom describing the cross-section (centroid) position and orientation. A consistent 1D-3D coupling scheme for this problem type is proposed, requiring to enforce both positional and rotational constraints. Since Boltzmann continua exhibit no inherent rotational degrees of freedom, suitable definitions of orthonormal triads are investigated that are representative for the orientation of material directions within the 3D solid. While the rotation tensor defined by the polar decomposition of the deformation gradient appears as a natural choice and will even be demonstrated to represent these material directions in a $$L_2$$ L 2 -optimal manner, several alternative triad definitions are investigated. Such alternatives potentially allow for a more efficient numerical evaluation. Moreover, objective (i.e. frame-invariant) rotational coupling constraints between beam and solid orientations are formulated and enforced in a variationally consistent manner based on either a penalty potential or a Lagrange multiplier potential. Eventually, finite element discretization of the solid domain, the embedded beams, which are modeled on basis of the geometrically exact beam theory, and the Lagrange multiplier field associated with the coupling constraints results in an embedded mortar-type formulation for rotational and translational constraint enforcement denoted as full beam-to-solid volume coupling (BTS-FULL) scheme. Based on elementary numerical test cases, it is demonstrated that a consistent spatial convergence behavior can be achieved and potential locking effects can be avoided, if the proposed BTS-FULL scheme is combined with a suitable solid triad definition. Eventually, real-life engineering applications are considered to illustrate the importance of consistently coupling both translational and rotational degrees of freedom as well as the upscaling potential of the proposed formulation. This allows the investigation of complex mechanical systems such as fiber-reinforced composite materials, containing a large number of curved, slender fibers with arbitrary orientation embedded in a matrix material.

Many composite materials are based on 1D fibers being embedded into 3D solid volumes, e.g. carbon-fiber reinforced plastics in aerospace engineering or fiber-reinforced concrete in civil engineering to name only two prominent examples. The present contribution highlights the most important numerical methods and algorithmic building blocks for an efficient analysis of such systems based on cutting-edge finite element formulations for nonlinear beams and a novel beam-to-solid volume coupling approach inspired by classical mortar methods. A particular emphasis is put on the efficient parallel implementation for large-scale simulations, which includes suitable procedures for domain partitioning and geometry-based search.

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