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Jian Cao

Publications and source records attributed to Jian Cao.

At least 19 recordsLinked to original sources
arXiv2026

Self-Correcting Long-Horizon Search Agents via Tree-Structured Memory

Large language model (LLM)-based search agents answer questions through multi-step interactions with external environments. However, providing complete execution trajectories to the LLM causes unbounded context growth and introduces noise. Existing compression methods reduce context at the cost of important details and often replace erroneous facts without repairing downstream reasoning derived from them. To address this problem, we propose ReTree, a self-correcting tree-structured memory mechanism for search agents. ReTree constructs a bounded per-step reasoning context while preserving source-linked evidence. It models search as an evidence tree whose nodes store bounded summaries, evidence, and revision histories. When newly retrieved evidence contradicts an earlier claim, ReTree traces back to the node where the claim was introduced, replaces outdated evidence, regenerates summaries, prunes affected branches, and resumes search. Source-grounded evidence provenance supports reliable conflict localization and keeps final claims traceable to retrieved passages. Experiments on four public question-answering and search benchmarks show that ReTree consistently outperforms Full-Trajectory ReAct, improving answer accuracy by up to 25.6 percentage points (pp); the average maximum per-step reasoning context of Full-Trajectory ReAct is $1.27$--$1.51\times$ that of ReTree. These results establish ReTree as an effective self-correcting memory abstraction for long-horizon search.

cs.AI↗
arXiv2026

Continue or Replan? Bernoulli-Continuation Policy Learning for Adaptive Horizon Execution

Existing chunk-based Vision-Language-Action (VLA) models execute a fixed number of actions (i.e., execution horizon) before replanning, turning replanning into a task-agnostic periodic schedule that is independent of task progress. As a result, when no replanning boundary falls before a critical manipulation stage, it is executed from a stale chunk rather than a freshly replanned one. To address this limitation, we propose Bernoulli-Continuation Policy (BCP), a lightweight, plug-and-play framework for adaptive horizon execution that keeps the base VLA frozen. Given a fixed-length action chunk, its continuation head decomposes execution-horizon selection into a sequence of continue-or-replan decisions, which imposes an ordinal, prefix-sharing inductive bias over candidate horizons rather than treating them as independent classes. Since the optimal horizon for each chunk is not observable, we train this head with reinforcement learning from trajectory-level outcomes and introduce a Replanning-Efficiency Reward that jointly rewards task success and efficient VLA usage, discouraging the policy from collapsing to unnecessarily short horizons. On RoboTwin 2.0 with LingBot-VLA as the base policy, BCP improves the average success rate by +11.08% on 13 low-success tasks and from 89.88% to 93.94% (+4.06%) across all 50 tasks. Although trained only under the Clean setting, BCP generalizes to the Randomized setting, raising the average success rate by +4.06%. It also transfers to a different base policy $\pi_{0.5}$, achieving a better result on LIBERO (+1.7%) and, notably, on the harder LIBERO-PRO (+6.8%). On a real robot, BCP lifts success from 74% to 92% and from 44% to 84% on two manipulation tasks. Meanwhile, its negligible overhead, combined with higher success, makes BCP's overall runtime even lower than the fixed-horizon baselines.

cs.RO↗
arXiv2026

Thermo-Structural Topology Optimization Considering Nonlinear Creep

Creep is a primary life-limiting mechanism for metallic components operating at high temperature, producing permanent deformation under sustained loads even when stresses remain below yield. The design of structures to minimize this deformation is critical to extending the service life of components. Incorporating creep into topology optimization (TO) remains open because the response is nonlinear, history-dependent, and thermomechanically coupled, and prior work often relies on linear viscoelastic models, which do not capture the behavior of metals at high temperatures. To bridge this gap, we introduce a differentiable thermo-structural TO framework. The approach considers creep deformation using the Norton model and leverages JAX's automatic differentiation to perform adjoint sensitivity analysis, enabling efficient gradient-based optimization. The transient material response is solved via a backward Euler scheme over a prescribed service life. Our objective is to minimize creep deformation subject to a volume constraint. We first demonstrate the framework on canonical two-dimensional benchmarks, showing that the proposed formulation significantly reduces permanent deformation compared to designs optimized solely for elastic stiffness. We then pose, as a challenge problem, the compositional design of a three-dimensional graded material turbine blade in which the local mixture of two candidate alloys is optimized. This challenge problem exercises the full capability of the framework, including transient nonlinear creep, coupled thermal loading, three-dimensional geometry, and gradient-based multi-material design, highlighting the need for creep-aware design in high-temperature applications.

cs.CE↗
arXiv2026

Shedding light on the nature of $\phi(2170)$ with the parton and hadron cascade model PACIAE

The nature of $\phi(2170)$ remains open. We simulate its production in $e^+e^-$ collisions at $\sqrt{s}=4.95$ GeV using PACIAE 4.0, which sequentially generates the final partonic state (FPS) and the final hadronic state (FHS). While previous studies have interpreted $\phi(2170)$ as an $ss\bar{s}\bar{s}$ or a $u\bar{u}s\bar{s}$ state, the $U(1)$ anomaly coupling allows non-strange quarks to couple to a vector $s\bar{s}$ component via soft-gluon interactions. This motivates us to also explore the $d\bar{d}s\bar{s}$ tetraquark configuration. In addition, we consider $\phi(2170)$ as an excited strangeonium state, an $s\bar{s}g$ hybrid state, a $\bar{\Lambda}\Lambda$ bound state, and a $\phi K^+K^-$ resonance state. The strangeonium, hybrid, and tetraquark candidates are formed by coalescing their constituent partons in the FPS using the dynamically constrained phase-space coalescence model. The $\bar{\Lambda}\Lambda$ and $\phi K^+K^-$ states are produced via recombination of their constituent hadrons in the FHS. We calculate the orbital angular momentum quantum number of each candidate in its rest frame and perform spectral classification. Given $J^{PC}=1^{--}$, $\phi(2170)$ can be interpreted as a $D$-wave $s\bar{s}$, a $P$-wave $s\bar{s}g$, a $P$-wave $u\bar{u}s\bar{s}/d\bar{d}s\bar{s}/ss\bar{s}\bar{s}$, an $S$-wave $\bar{\Lambda}\Lambda$, or an $S$-wave $\phi K^+K^-$ state. The yields of the $D$-wave $s\bar{s}$, $P$-wave $s\bar{s}g$, $u\bar{u}s\bar{s}$ and $d\bar{d}s\bar{s}$ states are of order $10^{-4}$; those for the $S$-wave $\bar{\Lambda}\Lambda$ and $\phi K^+K^-$ states are of order $10^{-5}$; while the $P$-wave $ss\bar{s}\bar{s}$ yield is of order $10^{-6}$. Moreover, significant discrepancies are observed in the rapidity distributions and the $p_T$ spectra among the various candidates. These discrepancies could serve as valuable criteria for unraveling the nature of $\phi(2170)$.

hep-ph↗
arXiv2026

JAX-FEM-ANISO: Differentiable GPU-Accelerated Finite Element Framework for Inverse Identification of Finite-Strain Anisotropic Plasticity

We present a fully differentiable, GPU-accelerated finite element framework JAX-FEM-ANISO, for forward simulation and inverse parameter identification of finite-strain anisotropic plasticity. Built on JAX-FEM, the framework exploits modern accelerator architectures by parallelizing the three major computational bottlenecks in nonlinear FEM: elemental weak-form and tangent-stiffness evaluation, global sparse matrix assembly, and sparse linear solution. For a large-scale forward problem with 3 million degrees of freedom, JAX-FEM-ANISO on a single NVIDIA H100 GPU achieves up to 9.4$\times$ speed-up over a 24-core CPU Abaqus baseline. Automatic differentiation is applied through the constitutive update and solver workflow, providing consistent Jacobians for complex constitutive models without manual derivation and accurate gradients for PDE-constrained inverse analysis. Compared with finite differences, the JAX-AD gradients avoid step-size sensitivity and provide the required sensitivities at substantially lower computational cost. For inverse characterization, we combine information-rich, topology-optimized heterogeneous specimens with full-field displacement data to identify advanced constitutive model parameters from a single test, replacing what would otherwise require many conventional experiments. We demonstrate accurate recovery of anisotropic yield and hardening parameters in progressively challenging settings, including uniform and spatially varying material properties. The resulting AD-based formulation enables efficient optimization in high-dimensional parameter spaces where finite-difference approaches are computationally infeasible. These results establish differentiable, GPU-accelerated FEM as a practical high-throughput engine for simulation, characterization, and optimization workflows in advanced manufacturing.

cs.CE↗
arXiv2026

MOSAIC: Mobile Object Segmentation under Adverse Imaging Conditions for Rapid L-PBF Keyhole Behavior Characterization

In laser powder bed fusion (L-PBF) processes, the rapid evolution of gas and fluid interactions complicates our ability to properly monitor or control the process, with unstable keyholes leading to porosity and spatter formation. High-speed operando x-ray imaging of the keyhole has been used to better understand the impact of these interactions on the monitoring and control of the L-PBF process. MOSAIC, a Mobile Object Segmentation algorithm for experiments under Adverse Imaging Conditions, is designed to perform rapid analysis of keyhole dynamics during active beamline experimentation without needing time consuming manual labeling or model training. Validation studies performed on 12 unique samples proved the robustness of MOSAIC with an average F1 score of 0.894 and a precision of 0.953 when compared to manually segmented images, performing equally or better than the SAM and YOLO machine learning methods tested. MOSAIC is efficient, processing frames cropped to a moving window approximately 150x250 pixels at 19.9 milliseconds per image on CPU, compared to 54 and 5284 milliseconds per image for inference on CPU for YOLO and SAM models.

eess.IV↗
arXiv2026

Permutation-preserving Functions and Neural Vecchia Covariance Kernels

We introduce a novel framework for constructing scalable and flexible covariance kernels for Gaussian processes (GPs) by directly learning the covariance structure under a regression-type parameterization induced by Vecchia approximations, using deep neural architectures. Specifically, we model kriging coefficients and conditional standard deviations, deterministic quantities that uniquely characterize the covariance, providing stable and informative learning targets. Exploiting the permutation-equivariant structure of conditioning sets in the Vecchia factorization, we derive a universal representation for permutation-preserving functions and design neural architectures that respect this symmetry, leading to improved training stability and data efficiency. The proposed approach enables expressive, non-stationary kernel learning while maintaining computational scalability, thereby bridging classical GP methodology with modern deep learning.

stat.ML↗
arXiv2026

Scalable generative modeling of non-Gaussian spatio-temporal fields via autoregressive Gaussian processes

Generative modeling of spatio-temporal fields is crucial for a variety of applications, including stochastic weather generators and climate-model surrogates. However, many such fields exhibit complex dependence structures that vary across space and time and are nonlinear, resulting in nonstationary and non-Gaussian joint distributions. Our approach represents the joint density of a spatio-temporal field as a product of univariate conditional distributions and models these conditionals using Gaussian processes within an autoregressive transport-map construction. This prior distribution provides regularization, making our method suitable for a small number of training samples. Data-dependent sparsity in the conditioning sets ensures scalability to high-dimensional distributions. We also propose a variant of the method designed to sample or predict forward in time from a given incomplete space-time trajectory. We demonstrate the accuracy and scalability of our approach on non-Gaussian climate-model output with tens of millions of data points.

stat.ME↗
arXiv2026

WaveTune: Wave-aware Bilinear Modeling for Efficient GPU Kernel Auto-tuning

The rapid adoption of Large Language Models (LLMs) has made GPU inference efficiency an increasingly critical system concern. The runtime of LLM workloads is largely dominated by tile-based kernels, particularly General Matrix Multiplications (GEMMs). Although these kernels are highly optimized, their performance remains sensitive to a large space of runtime parameters, such as tile sizes and pipeline stages. The interaction between these parameters and hardware resources leads to a non-convex optimization landscape. Existing approaches to parameter configuration -- including search-based auto-tuning, heuristic rules, and learned cost models -- face a fundamental trade-off between performance optimality and runtime efficiency. In this paper, we present WaveTune, a wave-aware framework for runtime kernel auto-tuning. First, we introduce a unified mapping method to handle input diversity and decompose the configuration space to manage high dimensionality. Second, we develop an analytical wave-aware bilinear model that accurately predicts kernel latency. Third, we design a sparse sampling scheme based on wave structures and a lightweight dual-table retrieval mechanism to minimize runtime overhead. As a result, WaveTune enables precise and efficient runtime configuration for GPU kernels. Across three representative kernels and five GPU architectures, WaveTune consistently achieves near-optimal kernel performance, delivering up to 1.83x kernel-level speedup and up to 1.33x end-to-end TTFT reduction, while reducing runtime decision overhead by five orders of magnitude compared to exhaustive search. These results demonstrate that WaveTune effectively eliminates the traditional trade-off between configuration latency and execution optimality, providing a practical and robust solution for high-performance LLM inference.

cs.PF↗
arXiv2026

Hestia: Hyperthread-Level Scheduling for Cloud Microservices with Interference-Aware Attention

Modern cloud servers routinely co-locate multiple latency-sensitive microservice instances to improve resource efficiency. However, the diversity of microservice behaviors, coupled with mutual performance interference under simultaneous multithreading (SMT), makes large-scale placement increasingly complex. Existing interference aware schedulers and isolation techniques rely on coarse core-level profiling or static resource partitioning, leaving asymmetric hyperthread-level heterogeneity and SMT contention dynamics largely unmodeled. We present Hestia, a hyperthread-level, interference-aware scheduling framework powered by self-attention. Through an extensive analysis of production traces encompassing 32,408 instances across 3,132 servers, we identify two dominant contention patterns -- sharing-core (SC) and sharing-socket (SS) -- and reveal strong asymmetry in their impact. Guided by these insights, Hestia incorporates (1) a self-attention-based CPU usage predictor that models SC/SS contention and hardware heterogeneity, and (2) an interference scoring model that estimates pairwise contention risks to guide scheduling decisions. We evaluate Hestia through large-scale simulation and a real production deployment. Hestia reduces the 95th-percentile service latency by up to 80\%, lowers overall CPU consumption by 2.3\% under the same workload, and surpasses five state-of-the-art schedulers by up to 30.65\% across diverse contention scenarios.

cs.DC↗
arXiv2026

PipeWeave: Synergizing Analytical and Learning Models for Unified GPU Performance Prediction

The rapid expansion of Transformer-based large language models has dramatically increased the need for high-performance GPUs. As a result, there is growing demand for fast, accurate, and widely generalizable GPU performance models to support next-generation hardware selection and system-level exploration. However, current data-driven methods are limited, exhibiting poor generalization across hardware and inadequate modeling of complex production-level kernels common in modern inference stacks. To address these issues, we present PipeWeave, a unified GPU modeling framework. This approach first employs an analytical model to quantify a given kernel's demands on the GPU's heterogeneous instruction pipelines. These analytical features are then fed into a machine learning (ML) model to capture complex cross-pipeline interactions and resource dependencies, enabling high-fidelity performance prediction. Our evaluation across 11 GPU types from four generations of major architectures on two widely-used serving systems demonstrates that PipeWeave delivers high fidelity and strong generalizability. It achieves accurate predictions, with only 6.1% average error at the kernel level and 8.5% for end-to-end inference -- reducing the error of state-of-the-art methods by 6.7x and 4.4x, respectively. We also demonstrate PipeWeave's value "beyond simulation" by utilizing its performance ceiling to diagnose implementation shortcomings and guide the optimization of a production fused MoE Triton kernel, achieving up to 1.7x speedup. Code is available https://github.com/zksainx/pipeweave.

cs.PF↗
arXiv2026

STEP-LLM: Generating CAD STEP Models from Natural Language with Large Language Models

Computer-aided design (CAD) is vital to modern manufacturing, yet model creation remains labor-intensive and expertise-heavy. To enable non-experts to translate intuitive design intent into manufacturable artifacts, recent large language models-based text-to-CAD efforts focus on command sequences or script-based formats like CadQuery. However, these formats are kernel-dependent and lack universality for manufacturing. In contrast, the Standard for the Exchange of Product Data (STEP, ISO 10303) file is a widely adopted, neutral boundary representation (B-rep) format directly compatible with manufacturing, but its graph-structured, cross-referenced nature poses unique challenges for auto-regressive LLMs. To address this, we curate a dataset of ~40K STEP-caption pairs and introduce novel preprocessing tailored for the graph-structured format of STEP, including a depth-first search-based reserialization that linearizes cross-references while preserving locality and chain-of-thought(CoT)-style structural annotations that guide global coherence. We integrate retrieval-augmented generation to ground predictions in relevant examples for supervised fine-tuning, and refine generation quality through reinforcement learning with a specific Chamfer Distance-based geometric reward. Experiments demonstrate consistent gains of our STEP-LLM in geometric fidelity over the Text2CAD baseline, with improvements arising from multiple stages of our framework: the RAG module substantially enhances completeness and renderability, the DFS-based reserialization strengthens overall accuracy, and the RL further reduces geometric discrepancy. Both metrics and visual comparisons confirm that STEP-LLM generates shapes with higher fidelity than Text2CAD. These results show the feasibility of LLM-driven STEP model generation from natural language, showing its potential to democratize CAD design for manufacturing.

cs.AI↗
arXiv2026

Machine Learning-Driven Creep Law Discovery Across Alloy Compositional Space

Hihg-temperature creep characterization of structural alloys traditionally relies on serial uniaxial tests, which are highly inefficient for exploring the large search space of alloy compositions and for material discovery. Here, we introduce a machine-learning-assisted, high-throughput framework for creep law identification based on a dimple array bulge instrument (DABI) configuration, which enables parallel creep testing of 25 dimples, each fabricated from a different alloy, in a single experiment. Full-field surface displacements of dimples undergoing time-dependent creep-induced bulging under inert gas pressure are measured by 3D digital image correlation. We train a recurrent neural network (RNN) as a surrogate model, mapping creep parameters and loading conditions to the time-dependent deformation response of DABI. Coupling this surrogate with a particle swarm optimization scheme enables rapid and global inverse identification with sparsity regularization of creep parameters from experiment displacement-time histories. In addition, we propose a phenomenological creep law with a time-dependent stress exponent that captures the sigmoidal primary creep observed in wrought INCONEL 625 and extracts its temperature dependence from DABI test at multiple temperatures. Furthermore, we employ a general creep law combining several conventional forms together with regularized inversion to identify the creep laws for 47 additional Fe-, Ni-, and Co-rich alloys and to automatically select the dominant functional form for each alloy. This workflow combined with DABI experiment provides a quantitative, high-throughput creep characterization platform that is compatible with data mining, composition-property modeling, and nonlinear structural optimization with creep behavior across a large alloy design space.

cond-mat.mtrl-sci↗
arXiv2025

Efficient GPU-computing simulation platform JAX-PF for differentiable phase field model

We present JAX-PF, an open-source, GPU-accelerated, and differentiable Phase Field (PF) software package, supporting both explicit and implicit time stepping schemes. Leveraging the modern computing architecture JAX, JAX-PF achieves high performance through array programming and GPU acceleration, delivering ~5x speedup over PRISMS-PF with MPI (24 CPU cores) for systems with ~4.19 million degrees of freedom using explicit schemes, and scaling efficiently with implicit schemes for large-size problems. Furthermore, a key feature of JAX-PF is automatic differentiation (AD), eliminating manual derivations of free-energy functionals and Jacobians. Beyond forward simulations, JAX-PF demonstrates its potential in inverse design by providing sensitivities for gradient-based optimization. We demonstrate, for the first time, the calibration of PF material parameters using AD-based sensitivities, highlighting its capability for high-dimensional inverse problems. By combining efficiency, flexibility, and full differentiability, JAX-PF offers a fast, practical, and integrated tool for forward simulation and inverse design, advancing co-designing of material and manufacturing processes and supporting the goals of the Materials Genome Initiative.

physics.comp-ph↗
arXiv2025

GLOW: Graph-Language Co-Encoding for Agentic Workflow Performance Prediction

Agentic Workflows (AWs) have emerged as a promising paradigm for solving complex tasks. However, automatically generating high-quality AWs remains expensive because AW optimization requires evaluating a large number of candidate AWs via execution, resulting in high computational cost and latency. Recently, AW performance prediction has become a hot research topic to avoid costly execution-based evaluation, but existing methods primarily use Graph Neural Networks (GNNs) to model workflow structures and insufficiently capture the semantic relationships among agents. To address this limitation, we propose GLOW, a unified framework for AW performance prediction that combines the graph-structure modeling ability of GNNs with the topology-aware semantic encoding capability of LLMs. Specifically, a graph-oriented LLM is first built through instruction-tuning on graph understanding tasks to extract topology-aware semantic representations from descriptive text of AWs. Meanwhile, a GNN explicitly models the structural information of AWs and produces corresponding structural representations. The semantic and structural representations are then fused in a shared latent space using a Transformer-based fusion module. A contrastive learning strategy is further introduced to learn more discriminative representations for AWs. Experiments on the FLORA-Bench benchmark demonstrate that GLOW consistently outperforms state-of-the-art baselines in both prediction accuracy and ranking utility. Moreover, when integrated into the AFLOW, an automatic AW generation framework, GLOW reduces optimization time by 98.7% with only a 0.031 average score decrease across three datasets, showing its effectiveness as an efficient surrogate evaluator for AW optimization.

cs.LG↗
arXiv2025

LLM-SrcLog: Towards Proactive and Unified Log Template Extraction via Large Language Models

Log parsing transforms raw logs into structured templates containing constants and variables. It underpins anomaly detection, failure diagnosis, and other AIOps tasks. Current parsers are mostly reactive and log-centric. They only infer templates from logs, mostly overlooking the source code. This restricts their capacity to grasp dynamic log structures or adjust to evolving systems. Moreover, per-log LLM inference is too costly for practical deployment. In this paper, we propose LLM-SrcLog, a proactive and unified framework for log template parsing. It extracts templates directly from source code prior to deployment and supplements them with data-driven parsing for logs without available code. LLM-SrcLog integrates a cross-function static code analyzer to reconstruct meaningful logging contexts, an LLM-based white-box template extractor with post-processing to distinguish constants from variables, and a black-box template extractor that incorporates data-driven clustering for remaining unmatched logs. Experiments on two public benchmarks (Hadoop and Zookeeper) and a large-scale industrial system (Sunfire-Compute) show that, compared to two LLM-based baselines, LLM-SrcLog improves average F1-score by 2-17% and 8-35%. Meanwhile, its online parsing latency is comparable to data-driven methods and about 1,000 times faster than per-log LLM parsing. LLM-SrcLog achieves a near-ideal balance between speed and accuracy. Finally, we further validate the effectiveness of LLM-SrcLog through practical case studies in a real-world production environment.

cs.SE↗
arXiv2025

EDGC: Entropy-driven Dynamic Gradient Compression for Efficient LLM Training

Training large language models (LLMs) poses significant challenges regarding computational resources and memory capacity. Although distributed training techniques help mitigate these issues, they still suffer from considerable communication overhead. Existing approaches primarily rely on static gradient compression to enhance communication efficiency; however, these methods neglect the dynamic nature of evolving gradients during training, leading to performance degradation. Accelerating LLM training via compression without sacrificing performance remains a challenge. In this paper, we propose an entropy-driven dynamic gradient compression framework called EDGC. The core concept is to adjust the compression rate during LLM training based on the evolving trends of gradient entropy, taking into account both compression efficiency and error. EDGC consists of three key components.First, it employs a down-sampling method to efficiently estimate gradient entropy, reducing computation overhead. Second, it establishes a theoretical model linking compression rate with gradient entropy, enabling more informed compression decisions. Lastly, a window-based adjustment mechanism dynamically adapts the compression rate across pipeline stages, improving communication efficiency and maintaining model performance. We implemented EDGC on a 32-NVIDIA-V100 cluster and a 64-NVIDIA-H100 cluster to train GPT2-2.5B and GPT2-12.1B, respectively. The results show that EDGC significantly reduces communication latency and training time by up to 46.45% and 16.13% while preserving LLM accuracy.

cs.LG↗
arXiv2025

Adaptive Digital Twin of Sheet Metal Forming via Proper Orthogonal Decomposition-Based Koopman Operator with Model Predictive Control

Digital Twin (DT) technologies are transforming manufacturing by enabling real-time prediction, monitoring, and control of complex processes. Yet, applying DT to deformation-based metal forming remains challenging because of the strongly coupled spatial-temporal behavior and the nonlinear relationship between toolpath and material response. For instance, sheet-metal forming by the English wheel, a highly flexible but artisan-dependent process, still lacks digital counterparts that can autonomously plan and adapt forming strategies. This study presents an adaptive DT framework that integrates Proper Orthogonal Decomposition (POD) for physics-aware dimensionality reduction with a Koopman operator for representing nonlinear system in a linear lifted space for the real-time decision-making via model predictive control (MPC). To accommodate evolving process conditions or material states, an online Recursive Least Squares (RLS) algorithm is introduced to update the operator coefficients in real time, enabling continuous adaptation of the DT model as new deformation data become available. The proposed framework is experimentally demonstrated on a robotic English Wheel sheet metal forming system, where deformation fields are measured and modeled under varying toolpaths. Results show that the adaptive DT is capable of controlling the forming process to achieve the given target shape by effectively capturing non-stationary process behaviors. Beyond this case study, the proposed framework establishes a generalizable approach for interpretable, adaptive, and computationally-efficient DT of nonlinear manufacturing systems, bridging reduced-order physics representations with data-driven adaptability to support autonomous process control and optimization.

eess.SY↗