A machine learning assisted multifidelity modelling methodology to predict 3D stresses in the vicinity of design features in composite structures

Multifidelity global–local finite element (FE) analyses are typically used to predict damage initiation hotspots around repetitive design features in large composite structures, such as composite airframes. We propose the use of machine learning (ML) methods to accelerate these analyses. We demonstrate this ML assisted framework for the stress analysis of a hole in plate feature in an aerospace C-spar structure. To enable this framework, we develop the following original features: a computationally efficient sampling scheme; a work-equivalent boundary condition homogenisation scheme; a volume averaged ply-by-ply stress approach; and a sequential long-short term memory neural network reformulated from a time basis to a stacking sequence basis with further bi-directionality customisation. Overall, we show that the developed method results in high-accuracy prediction of 3D stresses, with over two orders of magnitude reduction in modelling and simulation time compared to FE analyses.