Image driven deep learning method with FFT solver for predicting the microscale full field stress of stochastic boundary composites

Abstract A novel image‐driven deep learning approach embedded with model‐data‐knowledge information can directly predict the full field stress distribution and mechanical properties of composites solely based on initial scanning geometry images. The fiber spatial distribution and morphological features are identified by Scanning Electron Microscopy (SEM) initially. An effective random fiber generation algorithm is further utilized to generate images database comprising equivalent geometric models of various microstructures. Subsequently, the geometry model images database is analyzed by fast Fourier transform (FFT) to produce the database including the elastic modulus parameters and full field stress distributions of composites with distinct microstructures. Finally, an innovative image‐learning comprehensive paradigm uniting convolutional neural networks and convolutional autoencoders is elaborated systematically to learn the inherent laws of geometry images and field images. The results show that the proposed method have capacity to effectively and accurately predict the elastic modulus and full field stress distributions combined with error analysis even for stochastic boundary composites. The proposed methodology is a symbiosis of cutting‐edge image learning and non‐destructive testing techniques for composites, which can directly use the local non‐destructive or scanning images of composite structural components to quickly obtain field information and further predict damage evolution online. Highlights Proposing a novel deep learning approach combined with FFT directly to predict stress distribution of stochastic boundary composites solely based on micro‐images. Adopting equivalent geometric models dispersed by higher pixels mesh density considering extreme thin interface. Incorporate adaptive algorithms for streamlined training optimization. An innovative integration of deep learning and non‐destructive testing technology for the stress distribution and properties prediction online.