Implementation of Principal Component Analysis (PCA)/Singular Value Decomposition (SVD) and Neural Networks in Constructing a Reduced-Order Model for Virtual Sensing of Mechanical Stress

This study presents the design and validation of a numerical method based on an AI-driven ROM framework for implementing stress virtual sensing. By leveraging Reduced-Order Models (ROMs), the research aims to develop a virtual stress transducer capable of the real-time monitoring of mechanical stresses in mechanical components previously analyzed with high-resolution FEM simulations under a wide range of multiple load scenarios. The ROM is constructed through neural networks trained on Finite Element Method (FEM) outputs from multiple scenarios, resulting in a simplified yet highly accurate model that can be easily implemented digitally. The ANN model achieves a prediction error of MAEtest=(0.04±0.06) MPa for the instantaneous mechanical stress predictions, evaluated over the entire range of stress values (0 to 5.32 MPa) across the component structure. The virtual sensor is capable of producing a quasi-instantaneous, detailed full stress map of the component in just 0.13 s using the ROM, for any combination of 4-load inputs, compared to the 6 min and 31 s required by the FEM. Thus, the approach significantly reduces computational complexity while maintaining a high degree of precision, enabling efficient real-time monitoring. The proposed method's effectiveness is demonstrated through rigorous ROM validation, underscoring its potential for stress control. This precise AI-driven procedure opens new horizons for predictive maintenance strategies centered on stress cycle monitoring.