Hybrid Shell-Beam Inverse Finite Element Method for the Shape Sensing of Stiffened Thin-Walled Structures: Formulation and Experimental Validation on a Composite Wing-Shaped Panel.

This work presents a novel methodology for the accurate and efficient elastic deformation reconstruction of thin-walled and stiffened structures from discrete strains. It builds on the inverse finite element method (iFEM), a variationally-based shape-sensing approach that reconstructs structural displacements by matching a set of analytical and experimental strains in a least-squares sense. As iFEM employs the finite element framework to discretize the structural domain and as the displacements and strains are approximated using element shape functions, the kind of element used influences the accuracy and efficiency of the iFEM analysis. This problem is addressed in the present work through a novel discretization scheme that combines beam and shell inverse elements to develop an iFEM model of the structure. Such a hybrid discretization paradigm paves the way for more accurate shape-sensing of geometrically complex structures using fewer sensor measurements and lower computational effort than traditional approaches. The hybrid iFEM is experimentally demonstrated in this work for the shape sensing of bending and torsional deformations of a composite stiffened wing panel instrumented with strain rosettes and fiber-optic sensors. The experimental results are accurate, robust, and computationally efficient, demonstrating the potential of this hybrid scheme for developing an efficient digital twin for online structural monitoring and control.

Delamination and Skin-Spar Debond Detection in Composite Structures Using the Inverse Finite Element Method.

This work presents a novel strategy for detecting and localizing intra- or inter-laminar damages in composite structures using surface-instrumented strain sensors. It is based on the real-time reconstruction of structural displacements using the inverse Finite Element Method (iFEM). The iFEM reconstructed displacements or strains are post-processed or 'smoothed' to establish a real-time healthy structural baseline. As damage diagnosis is based on comparing damaged and healthy data obtained using the iFEM, no prior data or information regarding the healthy state of the structure is required. The approach is applied numerically on two carbon fiber-reinforced epoxy composite structures: for delamination detection in a thin plate, and skin-spar debond detection in a wing box. The influence of measurement noise and sensor locations on damage detection is also investigated. The results demonstrate that the proposed approach is reliable and robust but requires strain sensors proximal to the damage site to ensure accurate predictions.

Experimental Shape Sensing and Load Identification on a Stiffened Panel: A Comparative Study.

The monitoring of loads and displacements during service life is proving to be crucial for developing a modern Structural Health Monitoring framework. The continuous monitoring of these physical quantities can provide fundamental information on the actual health status of the structure and can accurately guide pro-active condition-based maintenance operations, thus reducing the maintenance costs and extending the service life of the monitored structures. Pushed by these needs and by the simultaneous development in the field of strain sensing technologies, several displacement reconstruction and load identification methods have been developed that are based on discrete strain measurements. Among the different formulations, the inverse Finite Element Method (iFEM), the Modal Method (MM) and the 2-step method, the latter being the only one able to also compute the loads together with the displacements, have emerged as the most accurate and reliable ones. In this paper, the formulation of the three methods is summarized in order to set the numerical framework for a comparative study. The three methods are tested on the reconstruction of the external load and of the displacement field of a stiffened aluminium plate starting from experimentally measured strains. A fibre optic sensing system has been used to measure surface strains and an optimization procedure has been performed to provide the best fibre pattern, based on five lines running along the stiffeners' direction and with a back-to-back measuring scheme. Additional sensors are used to measure the applied force and the plate's deflection in some locations. The comparison of the results obtained by each method proves the extreme accuracy and reliability of the iFEM in the reconstruction of the deformed shape of the panel. On the other hand, the Modal Method leads to a good reconstruction of the displacements, but also exhibits a sensitivity to the choice of the modes considered for the specific application. Finally, the 2-step approach is able to correctly identify the loads and to reconstruct the displacements with an accuracy that depends on the modeling of the experimental setup.

Shape-Sensing of Beam Elements Undergoing Material Nonlinearities.

The use of in situ strain measurements to reconstruct the deformed shape of structures is a key technology for real-time monitoring. A particularly promising, versatile and computationally efficient method is the inverse finite element method (iFEM), which can be used to reconstruct the displacement field of beam elements, plate and shell structures from some discrete strain measurements. The iFEM does not require the knowledge of the material properties. Nevertheless, it has always been applied to structures with linear material constitutive behavior. In the present work, advances are proposed to use the method also for concrete structures in civil engineering field such as bridges normally characterized by material nonlinearities due to the behavior of both steel and concrete. The effectiveness of iFEM, for simply supported reinforced concrete beam and continuous beams with load conditions that determine the yielding of reinforcing steel, is studied. In order to assess the influence on displacements and strains reconstructions, different measurement stations and mesh configurations are considered. Hybrid procedures employing iFEM analysis supported by bending moment-curvature relationship are proposed in case of lack of input data in plastic zones. The reliability of the results obtained is tested and commented on to highlight the effectiveness of the approach.

Shape Sensing of Plate Structures Using the Inverse Finite Element Method: Investigation of Efficient Strain-Sensor Patterns.

Methods for real-time reconstruction of structural displacements using measured strain data is an area of active research due to its potential application for Structural Health Monitoring (SHM) and morphing structure control. The inverse Finite Element Method (iFEM) has been shown to be well suited for the full-field reconstruction of displacements, strains, and stresses of structures instrumented with discrete or continuous strain sensors. In practical applications, where the available number of sensors may be limited, the number and sensor positions constitute the key parameters. Understanding changes in the reconstruction quality with respect to sensor position is generally difficult and is the aim of the present work. This paper attempts to supplement the current iFEM modeling knowledge through a rigorous evaluation of several strain-sensor patterns for shape sensing of a rectangular plate. Line plots along various sections of the plate are used to assess the reconstruction quality near and far away from strain sensors, and the nodal displacements are studied as the sensor density increases. The numerical results clearly demonstrate the effectiveness of the strain sensors distributed along the plate boundary for reconstructing relatively simple displacement patterns, and highlight the potential of cross-diagonal strain-sensor patterns to improve the displacement reconstruction of more complex deformation patterns.

Application of Inverse Finite Element Method to Shape Sensing of Curved Beams.

Curved beam, plate, and shell finite elements are commonly used in the finite element modeling of a wide range of civil and mechanical engineering structures. In civil engineering, curved elements are used to model tunnels, arch bridges, pipelines, and domes. Such structures provide a more efficient load transfer than their straight/flat counterparts due to the additional strength provided by their curved geometry. The load transfer is characterized by the bending, shear, and membrane actions. In this paper, a higher-order curved inverse beam element is developed for the inverse Finite Element Method (iFEM), which is aimed at reconstructing the deformed structural shapes based on real-time, in situ strain measurements. The proposed two-node inverse beam element is based on the quintic-degree polynomial shape functions that interpolate the kinematic variables. The element is C2 continuous and has rapid convergence characteristics. To assess the element predictive capabilities, several circular arch structures subjected to static loading are analyzed, under the assumption of linear elasticity and isotropic material behavior. Comparisons between direct FEM and iFEM results are presented. It is demonstrated that the present inverse beam finite element is both efficient and accurate, requiring only a few element subdivisions to reconstruct an accurate displacement field of shallow and deep curved beams.