Background <p>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.</p> Objective <p>This study aims to construct a high-accuracy strain field for test monitoring.</p> Methods <p>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.</p> Results <p>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.</p> Conclusions <p>The DT-MFMD is validated to have a better application prospect for large deformation and complex strain field distribution.</p>

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

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

摘要

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.