Mesh Graph Neural Network Framework for Accelerating Finite Element Simulation for Arbitrary Geometries

Iterative design and optimization of large, complex structures require fast and accurate prediction of stress, displacement, and other fields. Finite element analysis (FEA) is computationally expensive for this task. Existing neural network surrogates often struggle with varying topologies and complex boundary conditions. This study proposes the novel Dual-Stream Heterogeneous Graph Neural Network (DS-HGNN) for full-field stress and displacement prediction in thin-walled structures, demonstrated on box beams made of stiffened panels. DS-HGNN operates on panel-level heterogeneous graph representations and introduces physics-guided edge states initialized from edge types, spatial information, and boundary kinematics. These states are updated through dual-stream message passing that separates longitudinal and transverse structural information while allowing cross-stream exchange. Geometry and loading effects are incorporated through Feature-wise Linear Modulation (FiLM)-conditioned 1-D spectral convolutions, and physical fields are reconstructed using a spectral-bypass low-rank readout. The model is evaluated on stiffened panel datasets with different geometries, boundary kinematics, loading conditions, and material nonlinear responses. DS-HGNN achieves the lowest stress and displacement RMSE compared with six benchmark heterogeneous graph neural network models. It also reaches comparable accuracy to the strongest benchmark models using 19%-38% fewer training samples. A targeted evaluation further shows that DS-HGNN captures yield and post-yield stress features.

Nonlinear finite element crash simulations are accurate but computationally expensive, limiting their use in iterative design optimisation. Machine-learning surrogate models based on graph neural networks (GNNs) offer a faster alternative. Message-passing GNNs are widely used for mesh simulation, and their shared node and edge update functions are relatively generalisable across varying graph structures. By contrast, non-shareable edge-specific aggregation layers can capture nonlinear relationships more accurately but usually require fixed graph connectivity, which limits generalisability. This paper presents Mask-Morph Graph U-Net (MMGUNet), a practical approach to addressing the limitation of hierarchical Graph U-Net architectures that use edge-specific downsampling and upsampling layers. Fixed coarse graph connectivity is required for edge-specific layers. To retain this while improving spatial correspondence, the proposed method morphs the coarsened graph hierarchy to each input mesh using feature-aligned barycentric parameterisation before constructing cross-graph edges. It further applies node masking during supervised pretraining, followed by parameter-efficient fine-tuning in which high-parameter edge-specific layers are frozen. The proposed approach is evaluated in in-distribution, out-of-distribution, and cross-component transfer settings using mean Euclidean distance and maximum intrusion percentage error. Results show that coarse-graph morphing improves test accuracy relative to a fixed-coarse-graph baseline, while masked supervised pretraining reduces the train-test discrepancy and improves data efficiency during transfer. The proposed model also achieves lower prediction error compared with external baselines. These results demonstrate a practical route toward reusable, data-efficient mesh-based surrogate modelling for crashworthiness design exploration.

Reconstructing local stress fields in heterogeneous microstructures under non-linear, history-dependent loading remains a major computational bottleneck in multi-scale simulations. We propose a coupled LSTM-GNN framework that links the temporal and spatial aspects of local stress field reconstruction. A Long Short-Term Memory network encodes macroscopic stress-strain sequences into a compact hidden state that captures the path-dependent constitutive response, while a physics-informed Graph Neural Network reconstructs the spatially-resolved stress field at each time step. We introduce a relative weighting strategy with linear warm-up to balance the data-driven reconstruction loss and a discrete divergence-based equilibrium penalty. This resolves the scale mismatch that prevents fixed-weight formulations from converging in the elasto-plastic regime. The model is trained on 10,000 non-proportional loading paths applied to a periodic plate-with-a-hole microstructure and von Mises elasto-plasticity. The model achieves three orders of magnitude speedup over finite element simulations and generalizes to loading sequences twice the training length, with 1.9% cumulative error. Because the graph relies on mesh connectivity instead of the specific element type, one trained surrogate can be applied directly without retraining to meshes with different element types and to both coarser and finer resolutions, while in all cases reproducing the high-fidelity quad-element FE field used during training. Indeed, the message passing characteristics inherent to GNN and MeshGraphNet architecture render the model mesh-agnostic. Analysis of the LSTM hidden states suggests a low-dimensional structure related to the internal state variables of the constitutive model.