A Strain Field Reconstruction Method Based on Digital Twin by Multi-Level Fusion of Multi-Type Data

IF 2.4 3区工程技术 Q2 MATERIALS SCIENCE, CHARACTERIZATION & TESTING

Experimental Mechanics Pub Date : 2025-04-11 DOI:10.1007/s11340-025-01183-0

B. Wang, X. Ke, J. Wang, K. Liu, Z. Song, J. Zhou, C. Zhou

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引用次数: 0

Abstract

Background

Finite element analysis (FEA), digital image correlation (DIC), and strain gauge are usually used for test monitoring. Reconstructed by FEA strain field and strain gauges, the fusion field (DT-SFRM) has higher accuracy than FEA, and DT-SFRM accuracy is acceptable for small structural deformation. However, large deformation of thin-walled structures is accompanied by complex strain field, and the difference in strain distribution between FEA and strain gauges data increases sharply. The low-accuracy FEA strain field and small amount of strain gauges lead to insufficient accuracy of DT-SFRM.

Objective

This study aims to construct a high-accuracy strain field for test monitoring.

Methods

A strain field reconstruction method based on digital twin (DT) by multi-level fusion of multi-type data (DT-MFMD) is proposed. Large number of relatively high-accuracy DIC data is used to improve global FEA strain field accuracy. The high-accuracy strain gauges are used to further improve fusion field accuracy of FEA and DIC. A tensile test of large opening plate shell (LOPS) is performed to verify the advantage of DT-MFMD.

Results

The AvgErr (6.6%) and MaxErr (23.5%) of DT-MFMD are 16.0% and 58.8% lower than those of DT-SFRM, and the DT-MFMD is less affected by large deformation. In addition, the strain gauges number of DT-MFMD reduces by more than 62.5% under the same accuracy goal compared with that of DT-SFRM.

Conclusions

The DT-MFMD is validated to have a better application prospect for large deformation and complex strain field distribution.

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基于数字孪生的多类型数据多级融合应变场重建方法

试验监测通常采用有限元分析（FEA）、数字图像相关（DIC）和应变片等方法。通过有限元应变场和应变片重建，融合场（DT-SFRM）具有比有限元分析更高的精度，对于较小的结构变形，DT-SFRM精度可以接受。然而，薄壁结构的大变形伴随着复杂的应变场，有限元分析与应变片数据之间的应变分布差异急剧增大。由于有限元应变场精度低，应变片数量少，导致DT-SFRM精度不足。目的建立用于试验监测的高精度应变场。方法提出基于数字孪生（DT）的多类型数据多级融合应变场重建方法（DT- mfmd）。为了提高整体有限元应变场精度，采用了大量相对高精度的DIC数据。采用高精度应变片进一步提高了FEA和DIC的融合场精度。通过大开口板壳（LOPS）的拉伸试验，验证了DT-MFMD的优势。结果DT-MFMD的AvgErr（6.6%）和MaxErr（23.5%）分别比DT-SFRM低16.0%和58.8%，且DT-MFMD受大变形影响较小。在相同精度目标下，DT-MFMD的应变片数量比DT-SFRM减少了62.5%以上。结论DT-MFMD在大变形、复杂应变场分布等方面具有较好的应用前景。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Experimental Mechanics 物理-材料科学：表征与测试

CiteScore

4.40

自引率

16.70%

发文量

111

审稿时长

3 months

期刊介绍： Experimental Mechanics is the official journal of the Society for Experimental Mechanics that publishes papers in all areas of experimentation including its theoretical and computational analysis. The journal covers research in design and implementation of novel or improved experiments to characterize materials, structures and systems. Articles extending the frontiers of experimental mechanics at large and small scales are particularly welcome. Coverage extends from research in solid and fluids mechanics to fields at the intersection of disciplines including physics, chemistry and biology. Development of new devices and technologies for metrology applications in a wide range of industrial sectors (e.g., manufacturing, high-performance materials, aerospace, information technology, medicine, energy and environmental technologies) is also covered.