EAAI Journal 2026 Journal Article
Machine learning-based prediction of crack growth path and remaining life by data-driven surrogate model with adaptive dynamic correction algorithm
- Wenyue Zhang
- Xiaoshun Yan
- Yongbo Shao
- Xudong Gao
- Wentao He
This paper proposes a high-fidelity surrogate model for rapid and accurate automatic crack propagation and remaining life prediction. The program is developed by establishing a machine learning-based surrogate model using a Multilayer Perceptron Neural Network, which incorporates linear elastic fracture mechanics theory and a dynamic adaptive correction algorithm. The training dataset of the high-fidelity surrogate model is generated through co-simulation of ABAQUS and FRANC3D, with Principal Component Analysis utilized to enhance training efficiency. A comprehensive comparative analysis is performed on training performance of various machine learning models. The adaptive dynamic correction algorithm is devised corresponding to different crack growth stages. The proposed data-driven surrogate model with the dynamic adaptive correction algorithm is applied to predict the crack growth paths and remaining life at different locations of an actual cracked flange joint. The correction algorithm is ultimately triggered following crack penetration, which achieves high predictive accuracy, with maximum post-correction errors below 2 % for the crack path and 1 % for the life prediction. The predicted results well consistently with the test set in terms of the stress intensity factor, crack growth path and remaining life, which demonstrates the robustness of the surrogate model and the accuracy of the adaptive dynamic correction algorithm.