arXiv subjects

Sima Farshbaf

Publications and source records attributed to Sima Farshbaf.

4 recordsLinked to original sources

arXiv2026

Machine learning enables roughness-driven inverse design of milling processes

Interest in applying data-driven approaches in manufacturing has grown significantly, particularly for mapping complex, high-dimensional relationships. The milling process is one area where predictive models can link influential parameters to surface roughness metrics prior to in situ operations. While this approach offers clear advantages, it faces challenges due to limited datasets and robustness issues in inverse design paradigms. To address these challenges, this paper proposes a machine learning (ML)-based framework for the inverse design of the surface milling process, with a focus on surface roughness as the design objective. The framework employs forward training of two ML models, a deep neural network (DNN) and a random forest (RF) ensemble, both developed using a high-fidelity synthetic dataset generated from a computational simulation framework. These trained models are integrated into a Bayesian optimization (BO) procedure to overcome the multiplicity problem arising from the many-to-one mapping inherent in the dataset. The approach identifies top-performing milling process configurations, considering both process and tool parameters, and presents them from the full solution space. The models achieve average relative errors below 5% when compared to reference results, thereby demonstrating the robustness and reliability of the proposed methodology.

cond-mat.other↗

arXiv2026

An efficient open-source framework for high-fidelity 3D surface topography and roughness prediction in milling

With the emergence of data-driven approaches in science, there is growing interest in their application to manufacturing, particularly in surface precision engineering. However, generating large datasets required for model training is often impractical experimentally due to high costs and the time-intensive nature of measurements. High-fidelity synthetic datasets offer a viable alternative if they can be generated both efficiently and accurately. To address this challenge, this paper presents an efficient framework for generating accurate 3D surface topographies and roughness indicators in milling operations using numerical methods. First, a conventional topography prediction model is developed based on the forward solution method (FSM). Building on this, an optimized computational algorithm is proposed to establish an efficient FSM with significantly improved performance. The model is validated against two independent sets of experimental results, assessing both prediction accuracy and computational efficiency. The results demonstrate acceptable prediction errors and an average computational speedup of 42.2x. The proposed open-source model provides a generalizable framework for large-scale analysis, enabling the generation of extensive datasets for data-driven surrogate modeling.

cs.CE↗

arXiv2026

AI Meets Plasticity: A Comprehensive Survey

Artificial intelligence (AI) is rapidly emerging as a new paradigm of scientific discovery, namely data-driven science, across nearly all scientific disciplines. In materials science and engineering, AI has already begun to exert a transformative influence, making it both timely and necessary to examine its interaction with materials plasticity. In this study, we present a holistic survey of the convergence between AI and plasticity, highlighting state-of-the-art AI methodologies employed to discover, construct surrogate models for, and emulate the plastic behavior of materials. From a materials science perspective, we examine cause-and-effect relationships governing plastic deformation, including microstructural characterization and macroscopic responses described through plasticity constitutive models. From the perspective of AI methodology, we review a broad spectrum of applied approaches, ranging from frequentist techniques such as classical machine learning (ML), deep learning (DL), and physics-informed models to probabilistic frameworks that incorporate uncertainty quantification and generative AI methods. These data-driven approaches are discussed in the context of materials characterization and plasticity-related applications. The primary objective of this survey is to develop a comprehensive and well-organized taxonomy grounded in AI methodologies, with particular emphasis on distinguishing critical aspects of these techniques, including model architectures, data requirements, and predictive performance within the specific domain of materials plasticity. By doing so, this work aims to provide a clear road map for researchers and practitioners in the materials community, while offering deeper physical insight and intuition into the role of AI in advancing materials plasticity and characterization, an area of growing importance in the emerging AI-driven era.

cond-mat.mtrl-sci↗

arXiv2025

Large deformation and collapse analysis of re-entrant auxetic and hexagonal honeycomb lattice structures subjected to tension and compression

Additively manufactured auxetic structures offer desirable qualities like lightweight, good energy absorption, excellent indentation resistance, high shear stiffness and fracture toughness among others. A wide range of materials from polymers to metals can be used to fabricate these structures. In contrast to conventional materials, auxetic structures exhibit negative Poisson's ratios. Hence, unique mechanical properties can be achieved by specific design. In this work, two types of structures, namely re-entrant auxetic and non-auxetic hexagonal honeycomb, are investigated. Large deformation analyses in both 2D plane strain and 3D are conducted using linear triangular and tetrahedral multi-field displacement-pressure elements. Hyperelastic with rate-independent plasticity constitutive models are utilized and calibrated with experimental uni-axial tensile test results. The structures are subjected to compression and tension at both transversal and longitudinal directions. The contact domain method is employed to capture both self-contact and the interaction between the structure and loading plates. The obtained results show consistency with the experimental data. The outcomes of the analyses regarding the re-entrant auxetic structure agree with the expected behavior, showing a negative value of Poisson's ratio and greater efficiency of energy absorption than the hexagonal honeycomb. By understanding the influence of the loading direction on the structural behavior, equivalent Poisson's ratio and energy absorption a reliable theoretical framework for prospective designs of the lattice materials can be established.

cond-mat.mtrl-sci↗