Automated Construction and Insertion of Layer-by Layer Finite Element Sub-Models of Damaged Composites

Finite element models of composite structures are generally shell-based and modeled at the laminate level. More detailed layer-by-layer lamina-level models are sometimes needed for representing joints or for modeling defect growth processes. We describe a method and toolkit for automating the creation and insertion of layerby-layer finite element sub-models of composite laminate. We focus in particular on representing damage captured from nondestructive evaluation (NDE) measurements. The method is based on scripting existing simulation and solid modeling tools (ABAQUS and ACIS). It works even on complicated, curved CAD models. The submodel location is identified by the intersection of a cylinder with the structure. We then execute a series of instructions to generate a new shell with the submodel region removed, generate the layer-by-layer submodel, and bond together the layers and models with desired boundary conditions and defects. The instructions represent the steps of lamination and bonding for creating the composite. The output of the method includes CAD models of the new shell and each lamina within the submodel, and a Python script for ABAQUS that will load the CAD models, bond them together, and apply the specified boundary conditions

Towards Foundational AI Models for Additive Manufacturing: Language Models for G-Code Debugging, Manipulation, and Comprehension

3D printing or additive manufacturing is a revolutionary technology that enables the creation of physical objects from digital models. However, the quality and accuracy of 3D printing depend on the correctness and efficiency of the G-code, a low-level numerical control programming language that instructs 3D printers how to move and extrude material. Debugging G-code is a challenging task that requires a syntactic and semantic understanding of the G-code format and the geometry of the part to be printed. In this paper, we present the first extensive evaluation of six state-of-the-art foundational large language models (LLMs) for comprehending and debugging G-code files for 3D printing. We design effective prompts to enable pre-trained LLMs to understand and manipulate G-code and test their performance on various aspects of G-code debugging and manipulation, including detection and correction of common errors and the ability to perform geometric transformations. We analyze their strengths and weaknesses for understanding complete G-code files. We also discuss the implications and limitations of using LLMs for G-code comprehension

A Deep Learning Framework for Design and Analysis of Surgical Bioprosthetic Heart Valves

Bioprosthetic heart valves (BHVs) are commonly used as heart valve replacements but they are prone to fatigue failure; estimating their remaining life directly from medical images is difficult. Analyzing the valve performance can provide better guidance for personalized valve design. However, such analyses are often computationally intensive. In this work, we introduce the concept of deep learning (DL) based finite element analysis (DLFEA) to learn the deformation biomechanics of bioprosthetic aortic valves directly from simulations. The proposed DL framework can eliminate the time-consuming biomechanics simulations, while predicting valve deformations with the same fidelity. We present statistical results that demonstrate the high performance of the DLFEA framework and the applicability of the framework to predict bioprosthetic aortic valve deformations. With further development, such a tool can provide fast decision support for designing surgical bioprosthetic aortic valves. Ultimately, this framework could be extended to other BHVs and improve patient care

Incorporation of composite defects from ultrasonic NDE into CAD and FE models

Fiber-reinforced composites are widely used in aerospace industry due to their combined properties of high strength and low weight. However, owing to their complex structure, it is difficult to assess the impact of manufacturing defects and service damage on their residual life. While, ultrasonic testing (UT) is the preferred NDE method to identify the presence of defects in composites, there are no reasonable ways to model the damage and evaluate the structural integrity of composites. We have developed an automated framework to incorporate flaws and known composite damage automatically into a finite element analysis (FEA) model of composites, ultimately aiding in accessing the residual life of composites and make informed decisions regarding repairs. The framework can be used to generate a layer-by-layer 3D structural CAD model of the composite laminates replicating their manufacturing process. Outlines of structural defects, such as delaminations, are automatically detected from UT of the laminate and are incorporated into the CAD model between the appropriate layers. In addition, the framework allows for direct structural analysis of the resulting 3D CAD models with defects by automatically applying the appropriate boundary conditions. In this paper, we show a working proof-of-concept for the composite model builder with capabilities of incorporating delaminations between laminate layers and automatically preparing the CAD model for structural analysis using a FEA software

Direct Immersogeometric Fluid Flow and Heat Transfer Analysis of Objects Represented by Point Clouds

Immersogeometric analysis (IMGA) is a geometrically flexible method that enables one to perform multiphysics analysis directly using complex computer-aided design (CAD) models. In this paper, we develop a novel IMGA approach for simulating incompressible and compressible flows around complex geometries represented by point clouds. The point cloud object's geometry is represented using a set of unstructured points in the Euclidean space with (possible) orientation information in the form of surface normals. Due to the absence of topological information in the point cloud model, there are no guarantees for the geometric representation to be watertight or 2-manifold or to have consistent normals. To perform IMGA directly using point cloud geometries, we first develop a method for estimating the inside-outside information and the surface normals directly from the point cloud. We also propose a method to compute the Jacobian determinant for the surface integration (over the point cloud) necessary for the weak enforcement of Dirichlet boundary conditions. We validate these geometric estimation methods by comparing the geometric quantities computed from the point cloud with those obtained from analytical geometry and tessellated CAD models. In this work, we also develop thermal IMGA to simulate heat transfer in the presence of flow over complex geometries. The proposed framework is tested for a wide range of Reynolds and Mach numbers on benchmark problems of geometries represented by point clouds, showing the robustness and accuracy of the method. Finally, we demonstrate the applicability of our approach by performing IMGA on large industrial-scale construction machinery represented using a point cloud of more than 12 million points.Comment: 30 pages + references; Accepted in Computer Methods in Applied Mechanics and Engineerin