Mesh Graph Neural Network Framework for Accelerating Finite Element Simulation for Arbitrary Geometries
Authors: Josiah D. Kunz, Kamal Choudhary
Organizations: Illinois College, Jacksonville, IL, USA · Department of Materials Science and Engineering, Whiting School of Engineering, The Johns Hopkins University, Baltimore, MD 21218, USA
Finite element analysis (FEA) is essential for structural design but remains computationally expensive, particularly when evaluating multiple design iterations or load scenarios. Machine learning surrogate models offer a promising alternative, yet most approaches struggle with a critical limitation: generalizing across varying geometries. This work presents a mesh graph network (MGN) for predicting von Mises stress fields in 2D structural components with arbitrary hole geometries. Unlike traditional machine learning approaches that use absolute node coordinates as features, the proposed model builds on existing MGN frameworks that encode node types (e.g., fixed boundary, free surface, hole edge), relative edge features (distance between neighbors), and global features (applied load). This architecture is inherently translation- and rotation-invariant, enabling generalization to unseen geometries without retraining. The MGN was trained on 11 plate geometries under 20 load conditions and evaluated on 7 unseen geometries and 3 unseen loads. In the most favorable case, the model achieves R2≥0.97 on an unseen geometry and unseen load, compared to R2≈0.01--0.86 for conventional models (Random Forest, Gradient Boosting , K-Nearest Neighbors) trained on identical data. However, even in less favorable cases, the MGN model still outperforms conventional models. This work extends the mesh-based simulation framework of Pfaff et al. (arXiv:2010.03409) to structural mechanics, demonstrating that graph neural networks can serve as efficient surrogates for finite element analysis across varying 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.
Finite Element Analysis (FEA) is widely used for transient mechanical simulations, but its high computational cost limits real-time and high-resolution applications. Deep learning surrogate models can reduce this cost; however, many existing approaches are restricted to steady-state prediction or cannot jointly predict Node- and Element-based Outputs (NEO) over time. The state-of-the-art DeepFEA framework has addressed these issues but remains limited to structured finite element (FE) meshes. To overcome this limitation, this study proposes DeepFEAv2, a deep learning surrogate framework that enables prediction of transient FEA simulations across different FE mesh topologies and element types. The main contributions of DeepFEAv2 are: (a) a module that uses the FE connectivity matrix to organize input features by element and arrange them into an input sequence guided by the mesh topology; (b) a novel neural network architecture designed to process the input sequence and jointly predict NEO over time; and (c) a FEA-informed optimization strategy for regularizing these NEO predictions. DeepFEAv2 was evaluated on structured and unstructured 3D linear elastic datasets, as well as on a pressure-driven aortic valve dataset. DeepFEAv2 achieved R^2 values up to 0.99 and normalized errors as low as 0.38%. Compared with DeepFEA, it achieved up to 38.0% relative increase in R^2 and up to 87.1% reduction in normalized error. DeepFEAv2 also performed inference up to three orders of magnitude faster than traditional FEA. These results demonstrate that DeepFEAv2 can efficiently model transient FEA simulations across increasingly complex FE settings, providing a scalable surrogate framework for transient FEA.
Georgios Triantafyllou, Panagiotis G. Kalozoumis, Dimitris K. Iakovidis
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.