Automation and Expert System Framework for Coupled Shell-Solid Finite Element Modeling of Complex Structures

Finite Element (FE) analysis is a powerful numerical technique widely utilized to simulate the real-world response of complex engineering structures. With the advancements in adaptive optimization frameworks, multi-fidelity (coupled shell-solid) FE models are increasingly sought during the early design stages where a large design space is being explored. This is because multi-fidelity models have the potential to provide accurate solutions at a much lower computational cost. However, the time and effort required to create accurate and optimal multi-fidelity models with acceptable meshes for highly complex structures is still significant and is a major bottleneck in the FE modeling process. Additionally, there is a significant level of subjectivity involved in the decision-making about the multi-fidelity element topology due to a high dependence on the analyst's experience and expertise, which often leads to disagreements between analysts regarding the optimal modeling approach and heavy losses due to schedule delays. Moreover, this analyst-to-analyst variability can also result in significantly different final engineering designs. Thus, there is a greater need to accelerate the FE modeling process by automating the development of robust and adaptable multi-fidelity models as well as eliminating the subjectivity and art involved in the development of multi-fidelity models. This dissertation presents techniques and frameworks for accelerating the finite element modeling process of multi-fidelity models. A framework for the automated development of multi-fidelity models with adaptable 2-D/3-D topology using the parameterized full-fidelity and structural fidelity models is presented. Additionally, issues related to the automated meshing of highly complex assemblies is discussed and a strategic volume decomposition technique blueprint is proposed for achieving robust hexahedral meshes in complicated assembly models. A comparison of the full-solid, full-shell, and different multi-fidelity models of a highly complex stiffened thin-walled pressure vessel under external and internal tank pressure is presented. Results reveal that automation of multi-fidelity model generation in an integrated fashion including the geometry creation, meshing and post-processing can result in considerable reduction in cost and efforts. Secondly, the issue of analyst-to-analyst variability is addressed using a Decision Tree (DT) based Fuzzy Inference System (FIS) for recommending optimal 2D-3D element topology for a multi-fidelity model. Specifically, the FIS takes the structural geometry and desired accuracy as inputs (for a range of load cases) and infers the optimal 2D-3D topology distribution. Once developed, the FIS can provide real-time optimal choices along with interpretability that provides confidence to the analyst regarding the modeling choices. The proposed techniques and frameworks can be generalized to more complex problems including non-linear finite element models and as well as adaptable mesh generation schemes.