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Additive manufacturing has been recognized as an industrial technological revolution for manufacturing, which allows fabrication of materials with complex three-dimensional (3D) structures directly from computer-aided design models. Using two or more constituent materials with different physical and mechanical properties, it becomes possible to construct interpenetrating phase composites (IPCs) with 3D interconnected structures to provide superior mechanical properties as compared to the conventional reinforced composites with discrete particles or fibers. The mechanical properties of IPCs, especially response to dynamic loading, highly depend on their 3D structures. In general, for each specified structural design, it could take hours or days to perform either finite element analysis (FEA) or experiments to test the mechanical response of IPCs to a given dynamic load. To accelerate the physics-based prediction of mechanical properties of IPCs for various structural designs, we employ a deep neural operator (DNO) to learn the transient response of IPCs under dynamic loading as surrogate of physics-based FEA models. We consider a 3D IPC beam formed by two metals with a ratio of Young’s modulus of 2.7, wherein random blocks of constituent materials are used to demonstrate the generality and robustness of the DNO model. To obtain FEA results of IPC properties, 5000 random time-dependent strain loads generated by a Gaussian process kennel are applied to the 3D IPC beam, and the reaction forces and stress fields inside the IPC beam under various loading are collected. Subsequently, the DNO model is trained using an incremental learning method with sequence-to-sequence training implemented in JAX, leading to a 100X speedup compared to widely used vanilla deep operator network models. After an offline training, the DNO model can act as surrogate of physics-based FEA to predict the transient mechanical response in terms of reaction force and stress distribution of the IPCs to various strain loads in one second at an accuracy of 98%. Also, the learned operator is able to provide extended prediction of the IPC beam subject to longer random strain loads at a reasonably well accuracy. Such superfast and accurate prediction of mechanical properties of IPCs could significantly accelerate the IPC structural design and related composite designs for desired mechanical properties.
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This content will become publicly available on August 17, 2026
Accelerating Electric-magnetic machine simulation using the Fourier Neural Operator (FNO)
Electrical machines traditionally rely on Finite Element Analysis (FEA) to evaluate or simulate their properties by solving the associated partial differential equations (PDEs). However, FEA is computationally costly, which limits its capability for rapid design iteration and real-time simulations. While recent surrogate models such as Physics-Informed Neural Networks (PINNs) have shown promise, they often suffer from slow convergence and scalability issues in complex geometries. In this paper, we propose the use of the Fourier Neural Operator (FNO) as a resolution-invariant surrogate model to significantly reduce the computation time required for FEA-based PDE solutions in electric machines. Previous research has demonstrated the FNO’s ability to learn mappings for time-sequence problems by approximating operators between function spaces. Building on this, we present a methodology to directly predict the later-state electromagnetic fields of a rotating interior permanent magnet (IPM) motor based on its earlier-stage data by approximating the underlying operator that governs these transitions. Our framework enables full-geometry modeling without relying on segmentation, preserving accuracy while dramatically improving computational efficiency. The model was trained and validated on an FEA dataset with multiple boundary conditions and motor configurations, demonstrating strong generalization across different designs and resolutions. Experimental results show that the proposed FNO method achieves a significant reduction in computational time compared to traditional FEA simulations while maintaining an acceptable level of accuracy. This study highlights the potential of neural operators for accelerating electromagnetic simulations, enabling faster design iterations and offering new possibilities for real-time and optimization-based applications in electric machine design.
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- Award ID(s):
- 2213852
- PAR ID:
- 10634656
- Publisher / Repository:
- American Society of Mechanical Engineers (ASME)
- Date Published:
- Format(s):
- Medium: X
- Location:
- Anaheim, CA, USA
- Sponsoring Org:
- National Science Foundation
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