arXiv:2506.20537cs.LG2025-06

用FEA校正PINN,加速激光熔融模拟且保持高精度

Physics-Informed Machine Learning Regulated by Finite Element Analysis for Simulation Acceleration of Melt Pool Dynamics in Laser Powder Bed Fusion

  • PINN结合FEA动态校正,捕捉熔池相变与复杂流动
  • 相比传统FEA计算速度提升显著,精度接近全量级仿真
  • 适合需要快速预测熔池行为的增材制造研发人员

高效模拟激光粉末床熔融(LPBF)过程对工艺预测至关重要,但传统有限元分析(FEA)存在计算成本高的问题。虽然物理信息神经网络(PINN)可用少量数据预测场变量并支持参数迁移,但在时变问题中因残差累积及难以捕捉LPBF过程中陡峭的空间-时间梯度,导致精度下降。为此,本文提出一种新型建模框架——FEA-调节物理信息神经网络(FEA-PINN),在保持FEA精度的前提下显著加速熔池动力学预测。该框架创新体现在两方面:其一,设计新策略使PINN可追踪粉-液-固相变过程,引入温度依赖材料属性、粉末床相变、马兰戈尼对流和熔池内自然对流;其二,在推理阶段融合校正性FEA模拟,强制物理一致性,抑制误差漂移,精准捕捉梯度变化。对比分析表明,FEA-PINN精度接近基准FEA,同时大幅降低计算开销。该框架已在单道扫描的LPBF基准FEA数据上验证有效。

原文摘要 · Abstract (English)

Efficient simulation of Laser Powder Bed Fusion (LPBF) is crucial for process prediction due to the lasting issue of high computational cost associated with traditional numerical methods such as finite element analysis (FEA). While a Physics-Informed Neural Network (PINN) can predict solution fields with small training data and enables the generalization of new process parameters via transfer learning, it suffers from accuracy degradation in time-dependent problems due to the accumulation of residual and the difficulty in capturing the steep spatial and temporal gradients inherent in the LPBF process. To overcome this issue, this study develops an efficient modeling framework, FEA-Regulated Physics-Informed Neural Network (FEA-PINN), to accelerate the prediction of melt pool dynamics phenomena in an LPBF process while maintaining the FEA accuracy. The innovation of FEA-PINN manifested itself in two aspects. First, a novel strategy has been developed within the PINN model to capture the dynamic phase change of powder-liquid-solid, enabling the tracking of material status during laser melting. The model further incorporates temperature-dependent material properties, phase change behavior of the powder bed, Marangoni convection, and natural convection within the melt pool. Second, the FEA-PINN framework integrates corrective FEA simulations during inference to enforce physical consistency, reduce error drift, and capture the steep gradients. A comparative analysis shows that FEA-PINN achieves accuracy comparable to FEA while significantly reducing computational cost. The framework has been validated against benchmark FEA data for single-track scanning in LPBF.

增材制造物理信息网络熔池模拟加速仿真

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