A plastic correction algorithm for full-field elasto-plastic finite element simulations: critical assessment of predictive capabilities and improvement by machine learning

Abstract This paper introduces a new local plastic correction algorithm that is aimed at accelerating elasto-plastic finite element (FE) simulations for structural problems exhibiting localised plasticity (around e.g. notches, geometrical defects). The proposed method belongs to the category of generalised multi-axial Neuber-type methods, which process the results of an elastic prediction point-wise in order to calculate an approximation of the full elasto-plastic solution. The proposed algorithm relies on a rule of local proportionality, which, in the context of J2 plasticity, allows us to express the plastic correction problem in terms of the amplitude of the full mechanical tensors only. This lightweight correction problem can be solved for numerically using a fully implicit time integrator that shares similarities with the radial return algorithm. The numerical capabilities of the proposed algorithm are demonstrated for a notched structure and a specimen containing a distribution of spherical pores, subjected to monotonic and cyclic loading. As a second point of innovation, we show that the proposed local plastic correction algorithm can be further accelerated by employing a simple meta-modelling strategy, with virtually no added errors. At last, we develop and investigate the merits of a deep-learning-based corrective layer designed to reduce the approximation error of the plastic corrector. A convolutional architecture is used to analyse the neighbourhoods of material points and outputs a scalar correction to the point-wise Neuber-type predictions. This optional brick of the proposed plastic correction methodology relies on the availability of a set of full elasto-plastic finite element solutions to be used as a training data-set.