Adaptive Finite Element Mesh Error Recovery for AM Simulation

The mesh is segmented into different regions with different resolutions. Fine mesh regions are applied only where high accuracy is needed (e.g., areas with complex geometry or high stress gradients), while coarse mesh regions are used in areas where lower accuracy is acceptable. This segmentation allows the simulation to maintain precision in critical areas while reducing overall computational burden.

The patent implements local quality by assigning different mesh densities to different spatial locations based on local requirements. Adaptive mesh refinement algorithms identify regions requiring fine resolution (such as areas with high stress concentrations or geometric complexity) and apply fine mesh only there, while using coarse mesh in other regions. This local differentiation resolves the contradiction by concentrating computational resources where they provide maximum benefit to accuracy.

Large complex models are segmented into smaller submodels or analysis regions that can be processed independently or in parallel. This segmentation allows the simulation framework to handle larger overall model sizes by dividing the computational task into manageable pieces, reducing the cubic scaling impact on runtime while maintaining the ability to simulate complex geometries.

The patent employs dynamic mesh adaptation where the mesh density and distribution are adjusted during the simulation process based on evolving stress fields, temperature gradients, or other physical parameters. This dynamic adjustment allows the model to maintain high accuracy in regions of interest while using coarser representation elsewhere, enabling simulation of larger and more complex parts without proportional increases in computational cost.