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We extend the laminate based framework of direct Deep Material Networks (DMNs) to treat suspensions of rigid fibers in a non-Newtonian solvent. To do so, we derive two-phase homogenization blocks that are capable of treating incompressible fluid phases and infinite material contrast. In particular, we leverage existing results for linear elastic laminates to identify closed form expressions for the linear homogenization functions of two-phase layered emulsions. To treat infinite material contrast, we rely on the repeated layering of two-phase layered emulsions in the form of coated layered materials. We derive necessary and sufficient conditions which ensure that the effective properties of coated layered materials with incompressible phases are non-singular, even if one of the phases is rigid. With the derived homogenization blocks and non-singularity conditions at hand, we present a novel DMN architecture, which we name the Flexible DMN (FDMN) architecture. We build and train FDMNs to predict the effective stress response of shear-thinning fiber suspensions with a Cross-type matrix material. For 31 fiber orientation states, six load cases, and over a wide range of shear rates relevant to engineering processes, the FDMNs achieve validation errors below 4.31% when compared to direct numerical simulations with Fast-Fourier-Transform based computational techniques. Compared to a conventional machine learning approach introduced previously by the consortium of authors, FDMNs offer better accuracy at an increased computational cost for the considered material and flow scenarios., Comment: Submitted to "International Journal for Numerical Methods in Engineering"

As an anode material for lithium-ion batteries, amorphous silicon offers a significantly higher energy density than the graphite anodes currently used. Alloying reactions of lithium and silicon, however, induce large deformation and lead to volume changes up to 300%. We formulate a thermodynamically consistent continuum model for the chemo-elasto-plastic diffusion-deformation behavior of amorphous silicon and it's alloy with lithium based on finite deformations. In this paper, two plasticity theories, i.e. a rate-independent theory with linear isotropic hardening and a rate-dependent one, are formulated to allow the evolution of plastic deformations and reduce occurring stresses. Using modern numerical techniques, such as higher order finite element methods as well as efficient space and time adaptive solution algorithms, the diffusion-deformation behavior resulting from both theories is compared. In order to further increase the computational efficiency, an automatic differentiation scheme is used, allowing for a significant speed up in assembling time as compared to an algorithmic linearization for the global finite element Newton scheme. Both plastic approaches lead to a more heterogeneous concentration distribution and to a change to tensile tangential Cauchy stresses at the particle surface at the end of one charging cycle. Different parameter studies show how an amplification of the plastic deformation is affected. Interestingly, an elliptical particle shows only plastic deformation at the smaller half axis. With the demonstrated efficiency of the applied methods, results after five charging cycles are also discussed and can provide indications for the performance of lithium-ion batteries in long term use.

Fiber-orientation tensors describe the relevant features of the fiber-orientation distribution compactly and are thus ubiquitous in injection-molding simulations and subsequent mechanical analyses. In engineering applications to date, the second-order fiber-orientation tensor is the basic quantity of interest, and the fourth-order fiber-orientation tensor is obtained via a closure approximation. Unfortunately, such a description limits the predictive capabilities of the modeling process significantly, because the wealth of possible fourth-order fiber-orientation tensors is not exploited by such closures, and the restriction to second-order fiber-orientation tensors implies artifacts. Closures based on the second-order fiber-orientation tensor face a fundamental problem - which fourth-order fiber-orientation tensors can be realized? In the literature, only necessary conditions for a fiber-orientation tensor to be connected to a fiber-orientation distribution are found. In this article, we show that the typically considered necessary conditions, positive semidefiniteness and a trace condition, are also sufficient for being a fourth-order fiber-orientation tensor in the physically relevant case of two and three spatial dimensions. Moreover, we show that these conditions are not sufficient in higher dimensions. The argument is based on convex duality and a celebrated theorem of D. Hilbert (1888) on the decomposability of positive and homogeneous polynomials of degree four. The result has numerous implications for modeling the flow and the resulting microstructures of fiber-reinforced composites, in particular for the effective elastic constants of such materials.

The manufacturing process of Sheet Molding Compound (SMC) influences the properties of a component in a non-deterministic fashion. To predict this influence on the mechanical performance, we develop a virtual process chain acting as a digital twin for SMC specimens from compounding to failure. More specifically, we inform a structural simulation with individual fields for orientation and volume fraction computed from a direct bundle simulation of the manufacturing process. The structural simulation employs an interpolated direct deep material network to upscale a tailored SMC damage model. We evaluate hundreds of virtual specimens and conduct a probabilistic analysis of the mechanical performance. We estimate the contribution to uncertainty originating from the process-induced inherent random microstructure and from varying initial SMC stack configurations. Our predicted results are in good agreement with experimental tensile tests and thermogravimetric analysis.

The onset of nonlinear effects in metals, such as plasticity and damage, is strongly influenced by the heterogeneous stress distribution at the grain level. This work is devoted to studying the local stress distribution of shear stresses resolved in the slip systems as the critical driving force for plastic deformations. Specific grain orientations with respect to load direction are investigated in the linear elastic regime and at incipient plastic deformations based on a large ensemble of microstructures. The elastic anisotropy of the single crystal is found to have a crucial influence on the scatter of the stress distribution, whereas the Young's modulus in the respective crystal direction governs the mean stress in the grain. It is further demonstrated that, for higher anisotropy, the shear stresses deviate from the normal distribution and are better approximated by a log-normal fit. Comparing the full-field simulations to the Maximum Entropy Method (MEM), reveals that the MEM provides an excellent prediction up to the second statistical moment in the linear elastic range. In a study on the spatial distribution of shear stresses, the grain boundary is identified as a region of pronounced stress fluctuations and as the starting point of yielding during the elastic-plastic transition.

We extend the FE-DMN method to fully coupled thermomechanical two-scale simulations of composite materials. In particular, every Gauss point of the macroscopic finite element model is equipped with a deep material network (DMN). Such a DMN serves as a high-fidelity surrogate model for full-field solutions on the microscopic scale of inelastic, non-isothermal constituents. Building on the homogenization framework of Chatzigeorgiou et al. [Int. J. Plast, vol. 81, pp. 18--39, 2016], we extend the framework of DMNs to thermomechanical composites by incorporating the two-way thermomechanical coupling, i.e., the coupling from the macroscopic onto the microscopic scale and vice versa, into the framework. We provide details on the efficient implementation of our approach as a user-material subroutine (UMAT). We validate our approach on the microscopic scale and show that DMNs predict the effective stress, the effective dissipation and the change of the macroscopic absolute temperature with high accuracy. After validation, we demonstrate the capabilities of our approach on a concurrent thermomechanical two-scale simulation on the macroscopic component scale.

In this work, we propose a fully coupled multiscale strategy for components made from short fiber reinforced composites, where each Gauss point of the macroscopic finite element model is equipped with a deep material network (DMN) which covers the different fiber orientation states varying within the component. These DMNs need to be identified by linear elastic precomputations on representative volume elements, and serve as high-fidelity surrogates for full-field simulations on microstructures with inelastic constituents. We discuss how to extend direct DMNs to account for varying fiber orientation, and propose a simplified sampling strategy which significantly speeds up the training process. To enable concurrent multiscale simulations, evaluating the DMNs efficiently is crucial. We discuss dedicated techniques for exploiting sparsity and high-performance linear algebra modules, and demonstrate the power of the proposed approach on an industrial-scale three-dimensional component. Indeed, the DMN is capable of accelerating two-scale simulations significantly, providing possible speed-ups of several magnitudes., Comment: Submitted to "Computer Methods in Applied Mechanics and Engineering"

For material modeling of microstructured media, an accurate characterization of the underlying microstructure is indispensable. Mathematically speaking, the overall goal of microstructure characterization is to find simple functionals which describe the geometric shape as well as the composition of the microstructures under consideration, and enable distinguishing microstructures with distinct effective material behavior. For this purpose, we propose using Minkowski tensors, in general, and the quadratic normal tensor, in particular, and introduce a computational algorithm applicable to voxel-based microstructure representations. Rooted in the mathematical field of integral geometry, Minkowski tensors associate a tensor to rather general geometric shapes, which make them suitable for a wide range of microstructured material classes. Furthermore, they satisfy additivity and continuity properties, which makes them suitable and robust for large-scale applications. We present a modular algorithm for computing the quadratic normal tensor of digital microstructures. We demonstrate multigrid convergence for selected numerical examples and apply our approach to a variety of microstructures. Strikingly, the presented algorithm remains unaffected by inaccurate computation of the interface area. The quadratic normal tensor may be used for engineering purposes, such as mean-field homogenization or as target value for generating synthetic microstructures.

Reduction of heat and friction losses is a proven approach to increase the engine efficiency. Therefore, and due to a stabilized, robust combustion, a specific adjustment of component temperatures is desirable in highly transient conditions. In this paper, a turbocharged SI engine is investigated numerically concerning the potential regulation of temperatures, including heat fluxes, only by controlling the water mass flow rate. Using two independent models, a simplified lumped capacity model and a detailed three-dimensional CFD-CHT simulation, an efficient, two-stage calculation method is suggested for an optimized determination of control strategies and their parameters. This complements existing published works which usually control more than one parameter, but use one model. Different control strategies, like feed forward or feedback controllers, are proposed and compared. In addition, a more holistic approach is presented performing a Monte Carlo simulation which evaluates temperatures, as well as hydraulic pumping losses. Using expedient control strategies and parameters, it could be shown that the engine temperatures can be effectively regulated within a wide range. The two different models show partly similar results, and the efficient, two-stage optimization method has proven its worth. However, there are some significant differences between simplified and detailed modelling which are worth mentioning.

A calculation method for engine temperatures is presented. Special focus is placed on the transient and scattering boundary conditions within the combustion chamber, including fired and coasting conditions, as well as the dynamic heat transfer of the water jacket. Model reduction is achieved with dimensional analysis and the application of probability density functions, which allows for a timescale separation. Stationary in-cylinder pressure measurements are used as input values and, according to the transient behavior, modified with an own part-load model. A turbocharged SI race engine is equipped with 70 thermocouples at various positions in proximity to the combustion chamber. Differentiating from already published works, the method deals with the transient engine behavior during a race lap, which undergoes a frequency range of 0.1-1 Hz. This includes engine speed build-ups under gear changes, torque variations, or the transition from fired to coasting conditions. Different thermal behaviors of various measuring positions can be simulated successfully. Additionally, cylinder individual temperature effects resulting from an unsymmetrical ignition sequence and different volumetric efficiencies with unequal residual gas can be predicted. Up to a few percent, the energy balance of the water jacket is fulfilled and variations of water inlet temperatures can be simulated accurately enough.