Adaptive hyper reduction for additive manufacturing thermal fluid analysis

Abstract Thermal fluid coupled analysis is essential to enable an accurate temperature prediction in additive manufacturing. However, numerical simulations of this type are time-consuming, due to the high non-linearity, the underlying large mesh size and the small time step constraints. This paper presents a novel adaptive hyper reduction method for speeding up these simulations. The difficulties associated with non-linear terms for model reduction are tackled by designing an adaptive reduced integration domain. The proposed online basis adaptation strategy is based on a combination of a basis mapping, enrichment by local residuals and a gappy basis reconstruction technique. The efficiency of the proposed method will be demonstrated by representative 3D examples of additive manufacturing models, including single-track and multi-track cases.