Physics-based digital twin updating and twin-based explainable crack identification of mechanical lap joint

Abstract

The mechanical joints, including the lap joint, weld, bolt, and pin, are vulnerable to fatigue failure because of stress concentration and internal flaws. Digital twin (DTw) strategies were proposed to prevent catastrophic system failure by fatigue damage in mechanical joints. In previous studies, the data-driven approach, such as deep learning and machine learning were utilized to estimate severity of the damage. However, it needs to improve its prediction accuracy because of insufficient data and physical interpretability. In this study, the physics-based digital twin model updating and twin-based crack identification of fatigue damage in riveted lap joints were proposed using lamb waves with consideration of uncertain crack growth path. The proposed approach is based on three techniques; (i) Data pre-processing, including filtering and optimization-based signal synchronization, (ii) Lamb-wave propagation analysis with sensor dynamics model and uncertain crack path, and (iii) Optimization based physics-based model updating and inference. In data pre-processing, the excitation frequency magnitude and truncation time are estimated using the observed actuator signal in the Lamb-wave test. The sensor dynamic model and model parameters are updated using the Bayesian optimization method to minimize both the errors in the predicted (${\hat{y}}_t$) and observed ($y_t$) wave signal and the errors in the inferred ($l^{*}$) and observed ($l$) crack length. The crack growth path is sampled based on angular and spline schemes to consider uncertain crack propagation paths. The validity of the proposed method is demonstrated using an open data set (2019 PHM society data challenge). The results conclude that the proposed digital twin approach can improve estimation accuracy considering both the crack growth path and sensor dynamics model.