Consistent machine learning for topology optimization with microstructure-dependent neural network material models

Additive manufacturing methods together with topology optimization have enabled the creation of multiscale structures with controlled spatially-varying material microstructure. However, topology optimization or inverse design of such structures in the presence of nonlinearities remains a challenge due to the expense of computational homogenization methods and the complexity of differentiably parameterizing the microstructural response. A solution to this challenge lies in machine learning techniques that offer efficient, differentiable mappings between the material response and its microstructural descriptors. This work presents a framework for designing multiscale heterogeneous structures with spatially varying microstructures by merging a homogenization-based topology optimization strategy with a consistent machine learning approach grounded in hyperelasticity theory. We leverage neural architectures that adhere to critical physical principles such as polyconvexity, objectivity, material symmetry, and thermodynamic consistency to supply the framework with a reliable constitutive model that is dependent on material microstructural descriptors. Our findings highlight the potential of integrating consistent machine learning models with density-based topology optimization for enhancing design optimization of heterogeneous hyperelastic structures under finite deformations.

Practical multi-fidelity machine learning: fusion of deterministic and Bayesian models

Multi-fidelity machine learning methods address the accuracy-efficiency trade-off by integrating scarce, resource-intensive high-fidelity data with abundant but less accurate low-fidelity data. We propose a practical multi-fidelity strategy for problems spanning low- and high-dimensional domains, integrating a non-probabilistic regression model for the low-fidelity with a Bayesian model for the high-fidelity. The models are trained in a staggered scheme, where the low-fidelity model is transfer-learned to the high-fidelity data and a Bayesian model is trained for the residual. This three-model strategy -- deterministic low-fidelity, transfer learning, and Bayesian residual -- leads to a prediction that includes uncertainty quantification both for noisy and noiseless multi-fidelity data. The strategy is general and unifies the topic, highlighting the expressivity trade-off between the transfer-learning and Bayesian models (a complex transfer-learning model leads to a simpler Bayesian model, and vice versa). We propose modeling choices for two scenarios, and argue in favor of using a linear transfer-learning model that fuses 1) kernel ridge regression for low-fidelity with Gaussian processes for high-fidelity; or 2) deep neural network for low-fidelity with a Bayesian neural network for high-fidelity. We demonstrate the effectiveness and efficiency of the proposed strategies and contrast them with the state-of-the-art based on various numerical examples. The simplicity of these formulations makes them practical for a broad scope of future engineering applications.

Neural topology optimization: the good, the bad, and the ugly

Neural networks (NNs) hold great promise for advancing inverse design via topology optimization (TO), yet misconceptions about their application persist. This article focuses on neural topology optimization (neural TO), which leverages NNs to reparameterize the decision space and reshape the optimization landscape. While the method is still in its infancy, our analysis tools reveal critical insights into the NNs' impact on the optimization process. We demonstrate that the choice of NN architecture significantly influences the objective landscape and the optimizer's path to an optimum. Notably, NNs introduce non-convexities even in otherwise convex landscapes, potentially delaying convergence in convex problems but enhancing exploration for non-convex problems. This analysis lays the groundwork for future advancements by highlighting: 1) the potential of neural TO for non-convex problems and dedicated GPU hardware (the "good"), 2) the limitations in smooth landscapes (the "bad"), and 3) the complex challenge of selecting optimal NN architectures and hyperparameters for superior performance (the "ugly").

Engineering software 2.0 by interpolating neural networks: unifying training, solving, and calibration

The evolution of artificial intelligence (AI) and neural network theories has revolutionized the way software is programmed, shifting from a hard-coded series of codes to a vast neural network. However, this transition in engineering software has faced challenges such as data scarcity, multi-modality of data, low model accuracy, and slow inference. Here, we propose a new network based on interpolation theories and tensor decomposition, the interpolating neural network (INN). Instead of interpolating training data, a common notion in computer science, INN interpolates interpolation points in the physical space whose coordinates and values are trainable. It can also extrapolate if the interpolation points reside outside of the range of training data and the interpolation functions have a larger support domain. INN features orders of magnitude fewer trainable parameters, faster training, a smaller memory footprint, and higher model accuracy compared to feed-forward neural networks (FFNN) or physics-informed neural networks (PINN). INN is poised to usher in Engineering Software 2.0, a unified neural network that spans various domains of space, time, parameters, and initial/boundary conditions. This has previously been computationally prohibitive due to the exponentially growing number of trainable parameters, easily exceeding the parameter size of ChatGPT, which is over 1 trillion. INN addresses this challenge by leveraging tensor decomposition and tensor product, with adaptable network architecture.

Gradient-free neural topology optimization

Gradient-free optimizers allow for tackling problems regardless of the smoothness or differentiability of their objective function, but they require many more iterations to converge when compared to gradient-based algorithms. This has made them unviable for topology optimization due to the high computational cost per iteration and high dimensionality of these problems. We propose a pre-trained neural reparameterization strategy that leads to at least one order of magnitude decrease in iteration count when optimizing the designs in latent space, as opposed to the conventional approach without latent reparameterization. We demonstrate this via extensive computational experiments in- and out-of-distribution with the training data. Although gradient-based topology optimization is still more efficient for differentiable problems, such as compliance optimization of structures, we believe this work will open up a new path for problems where gradient information is not readily available (e.g. fracture).

Continual learning for surface defect segmentation by subnetwork creation and selection

We introduce a new continual (or lifelong) learning algorithm called LDA-CP&S that performs segmentation tasks without undergoing catastrophic forgetting. The method is applied to two different surface defect segmentation problems that are learned incrementally, i.e. providing data about one type of defect at a time, while still being capable of predicting every defect that was seen previously. Our method creates a defect-related subnetwork for each defect type via iterative pruning and trains a classifier based on linear discriminant analysis (LDA). At the inference stage, we first predict the defect type with LDA and then predict the surface defects using the selected subnetwork. We compare our method with other continual learning methods showing a significant improvement -- mean Intersection over Union better by a factor of two when compared to existing methods on both datasets. Importantly, our approach shows comparable results with joint training when all the training data (all defects) are seen simultaneously

iPINNs: Incremental learning for Physics-informed neural networks

Physics-informed neural networks (PINNs) have recently become a powerful tool for solving partial differential equations (PDEs). However, finding a set of neural network parameters that lead to fulfilling a PDE can be challenging and non-unique due to the complexity of the loss landscape that needs to be traversed. Although a variety of multi-task learning and transfer learning approaches have been proposed to overcome these issues, there is no incremental training procedure for PINNs that can effectively mitigate such training challenges. We propose incremental PINNs (iPINNs) that can learn multiple tasks (equations) sequentially without additional parameters for new tasks and improve performance for every equation in the sequence. Our approach learns multiple PDEs starting from the simplest one by creating its own subnetwork for each PDE and allowing each subnetwork to overlap with previously learned subnetworks. We demonstrate that previous subnetworks are a good initialization for a new equation if PDEs share similarities. We also show that iPINNs achieve lower prediction error than regular PINNs for two different scenarios: (1) learning a family of equations (e.g., 1-D convection PDE); and (2) learning PDEs resulting from a combination of processes (e.g., 1-D reaction-diffusion PDE). The ability to learn all problems with a single network together with learning more complex PDEs with better generalization than regular PINNs will open new avenues in this field.

Cooperative data-driven modeling

Data-driven modeling in mechanics is evolving rapidly based on recent machine learning advances, especially on artificial neural networks. As the field matures, new data and models created by different groups become available, opening possibilities for cooperative modeling. However, artificial neural networks suffer from catastrophic forgetting, i.e. they forget how to perform an old task when trained on a new one. This hinders cooperation because adapting an existing model for a new task affects the performance on a previous task trained by someone else. The authors developed a continual learning method that addresses this issue, applying it here for the first time to solid mechanics. In particular, the method is applied to recurrent neural networks to predict history-dependent plasticity behavior, although it can be used on any other architecture (feedforward, convolutional, etc.) and to predict other phenomena. This work intends to spawn future developments on continual learning that will foster cooperative strategies among the mechanics community to solve increasingly challenging problems. We show that the chosen continual learning strategy can sequentially learn several constitutive laws without forgetting them, using less data to achieve the same error as standard training of one law per model.

Continual Prune-and-Select: Class-incremental learning with specialized subnetworks

The human brain is capable of learning tasks sequentially mostly without forgetting. However, deep neural networks (DNNs) suffer from catastrophic forgetting when learning one task after another. We address this challenge considering a class-incremental learning scenario where the DNN sees test data without knowing the task from which this data originates. During training, Continual-Prune-and-Select (CP&S) finds a subnetwork within the DNN that is responsible for solving a given task. Then, during inference, CP&S selects the correct subnetwork to make predictions for that task. A new task is learned by training available neuronal connections of the DNN (previously untrained) to create a new subnetwork by pruning, which can include previously trained connections belonging to other subnetwork(s) because it does not update shared connections. This enables to eliminate catastrophic forgetting by creating specialized regions in the DNN that do not conflict with each other while still allowing knowledge transfer across them. The CP&S strategy is implemented with different subnetwork selection strategies, revealing superior performance to state-of-the-art continual learning methods tested on various datasets (CIFAR-100, CUB-200-2011, ImageNet-100 and ImageNet-1000). In particular, CP&S is capable of sequentially learning 10 tasks from ImageNet-1000 keeping an accuracy around 94% with negligible forgetting, a first-of-its-kind result in class-incremental learning. To the best of the authors' knowledge, this represents an improvement in accuracy above 20% when compared to the best alternative method.

Adaptive Clustering-based Reduced-Order Modeling Framework: Fast and accurate modeling of localized history-dependent phenomena

This paper proposes a novel Adaptive Clustering-based Reduced-Order Modeling (ACROM) framework to significantly improve and extend the recent family of clustering-based reduced-order models (CROMs). This adaptive framework enables the clustering-based domain decomposition to evolve dynamically throughout the problem solution, ensuring optimum refinement in regions where the relevant fields present steeper gradients. It offers a new route to fast and accurate material modeling of history-dependent nonlinear problems involving highly localized plasticity and damage phenomena. The overall approach is composed of three main building blocks: target clusters selection criterion, adaptive cluster analysis, and computation of cluster interaction tensors. In addition, an adaptive clustering solution rewinding procedure and a dynamic adaptivity split factor strategy are suggested to further enhance the adaptive process. The coined Adaptive Self-Consistent Clustering Analysis (ASCA) is shown to perform better than its static counterpart when capturing the multi-scale elasto-plastic behavior of a particle-matrix composite and predicting the associated fracture and toughness. Given the encouraging results shown in this paper, the ACROM framework sets the stage and opens new avenues to explore adaptivity in the context of CROMs.