Reduced-Dimension Surrogate Modeling to Characterize the Damage Tolerance of Composite/Metal Structures

Complex engineering models are typically computationally demanding and defined by a high-dimensional parameter space challenging the comprehensive exploration of parameter effects and design optimization. To overcome this curse of dimensionality and to minimize computational resource requirements, this research demonstrates a user-friendly approach to formulating a reduced-dimension surrogate model that represents a high-dimensional, high-fidelity source model. This approach was developed specifically for a non-expert using commercially available tools. In this approach, the complex physical behavior of the high-fidelity source model is separated into individual, interacting physical behaviors. A separate reduced-dimension surrogate model is created for each behavior and then all are summed to formulate the reduced-dimension surrogate model representing the source model. In addition to a substantial reduction in computational resources and comparable accuracy, this method also provides a characterization of each individual behavior providing additional insight into the source model behavior. The approach encompasses experimental testing, finite element analysis, surrogate modeling, and sensitivity analysis and is demonstrated by formulating a reduced-dimension surrogate model for the damage tolerance of an aluminum plate reinforced with a co-cured bonded E-glass/epoxy composite laminate under four-point bending.