Reduced-Order B-Spline Framework Delivers 15.6x Speedup in Part-Scale AFSD Thermomechanical Simulation
The reduced-order AFSD thermomechanical framework achieves 11.8–15.6 imes wall-clock speedups on part-scale builds while preserving accuracy against full finite-element solutions. By combining B-spline thermal fields with inherent-strain residual stress recovery, the method directly addresses computational barriers in naval and aerospace sustainment applications. Further validation on experimental residual-stress measurements and extension to multi-physics coupling remain necessary next steps.
The framework represents transient temperature on a fixed Cartesian grid with quadratic B-spline basis functions while embedding arbitrary part geometries via smooth signed-distance material indicators. An offline thermo-elasto-plastic RVE supplies a calibrated eigenstrain field that is spatially scaled by the part-scale peak temperature history to recover residual stresses without repeated plasticity solves. Validation against published AFSD thermal data and two demonstration builds (four-layer thin wall and 20-layer hollow cylinder) showed thermal runtimes of 22 s versus 806 s and 0.148–0.152 h versus 1.8 h, respectively.
Saha et al.: Within 18 months the framework will be integrated into at least one commercial AFSD process-control software package, reducing full-build simulation time below 10 minutes on desktop hardware.
Sources (2)
- [1]Primary Source(https://arxiv.org/abs/2610.22375)
- [2]Supporting Source(https://doi.org/10.1016/j.addma.2023.103456)