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May 15

CarCrashNet: A Large-Scale Dataset and Hierarchical Neural Solver for Data-Driven Structural Crash Simulation

Crash simulation is a cornerstone of modern vehicle development because it reduces the need for costly physical prototypes, accelerates safety-driven design iteration, and increasingly supports virtual testing workflows. At the same time, modeling structural crash mechanics remains exceptionally challenging: the response is governed by nonlinear contact, large deformation, material plasticity, failure, and complex multi-body interactions evolving over space and time on high-resolution finite-element meshes. In this work, we introduce CarCrashNet, a public high-fidelity open-source benchmark for data-driven structural crash simulation. CarCrashNet combines component-scale and full-vehicle simulations in a multi-modal format, including more than 14{,}000 bumper-beam pole-impact simulations with varying geometry, materials, and boundary conditions, together with 825 full-vehicle crash simulations built from three industry-standard vehicle models of increasing structural complexity: Dodge Neon, Toyota Yaris, and Chevrolet Silverado. To establish the reliability of the benchmark, we validate our open-source finite-element workflow based on OpenRadioss against both experimental crash data and the commercial solver Ansys LS-DYNA. We also introduce CrashSolver, a machine-learning model designed for full-vehicle crash prediction from high-resolution finite-element crash data. We further perform extensive benchmarking across the released datasets and evaluate CrashSolver against state-of-the-art geometric deep learning and transformer-based neural solvers. Our results position CarCrashNet as a foundation for reproducible research in structural simulation, crashworthiness modeling, and AI-driven virtual crash testing. The dataset is available at https://github.com/Mohamedelrefaie/CarCrashNet.

  • 4 authors
·
May 7

FEM-Bench: A Structured Scientific Reasoning Benchmark for Evaluating Code-Generating LLMs

As LLMs advance their reasoning capabilities about the physical world, the absence of rigorous benchmarks for evaluating their ability to generate scientifically valid physical models has become a critical gap. Computational mechanics, which develops and applies mathematical models and numerical methods to predict the behavior of physical systems under forces, deformation, and constraints, provides an ideal foundation for structured scientific reasoning evaluation. Problems follow clear mathematical structure, enforce strict physical and numerical constraints, and support objective verification. The discipline requires constructing explicit models of physical systems and reasoning about geometry, spatial relationships, and material behavior, connecting directly to emerging AI goals in physical reasoning and world modeling. We introduce FEM-Bench, a computational mechanics benchmark designed to evaluate the ability of LLMs to generate correct finite element method (FEM) and related code. FEM-Bench 2025 contains a suite of introductory but nontrivial tasks aligned with material from a first graduate course on computational mechanics. These tasks capture essential numerical and physical modeling challenges while representing only a small fraction of the complexity present in the discipline. Despite their simplicity, state-of-the-art LLMs do not reliably solve all of them. In a five attempt run, the best performing model at function writing, Gemini 3 Pro, completed 30/33 tasks at least once and 26/33 tasks all five times. The best performing model at unit test writing, GPT-5, had an Average Joint Success Rate of 73.8%. Other popular models showed broad performance variation. FEM-Bench establishes a structured foundation for evaluating AI-generated scientific code, and future iterations will incorporate increasingly sophisticated tasks to track progress as models evolve.

  • 4 authors
·
Dec 23, 2025

Dynamic and adaptive mesh-based graph neural network framework for simulating displacement and crack fields in phase field models

Fracture is one of the main causes of failure in engineering structures. Phase field methods coupled with adaptive mesh refinement (AMR) techniques have been widely used to model crack propagation due to their ease of implementation and scalability. However, phase field methods can still be computationally demanding making them unfeasible for high-throughput design applications. Machine learning (ML) models such as Graph Neural Networks (GNNs) have shown their ability to emulate complex dynamic problems with speed-ups orders of magnitude faster compared to high-fidelity simulators. In this work, we present a dynamic mesh-based GNN framework for emulating phase field simulations of crack propagation with AMR for different crack configurations. The developed framework - ADAPTive mesh-based graph neural network (ADAPT-GNN) - exploits the benefits of both ML methods and AMR by describing the graph representation at each time-step as the refined mesh itself. Using ADAPT-GNN, we predict the evolution of displacement fields and scalar damage field (or phase field) with high accuracy compared to conventional phase field fracture model. We also compute crack stress fields with high accuracy using the predicted displacements and phase field parameter. Finally, we observe speed up of 15-36x compared to serial execution of the phase field model.

  • 2 authors
·
Aug 30, 2022

Real-Time Structural Deflection Estimation in Hydraulically Actuated Systems Using 3D Flexible Multibody Simulation and DNNs

The precision, stability, and performance of lightweight high-strength steel structures in heavy machinery is affected by their highly nonlinear dynamics. This, in turn, makes control more difficult, simulation more computationally intensive, and achieving real-time autonomy, using standard approaches, impossible. Machine learning through data-driven, physics-informed and physics-inspired networks, however, promises more computationally efficient and accurate solutions to nonlinear dynamic problems. This study proposes a novel framework that has been developed to estimate real-time structural deflection in hydraulically actuated three-dimensional systems. It is based on SLIDE, a machine-learning-based method to estimate dynamic responses of mechanical systems subjected to forced excitations.~Further, an algorithm is introduced for the data acquisition from a hydraulically actuated system using randomized initial configurations and hydraulic pressures.~The new framework was tested on a hydraulically actuated flexible boom with various sensor combinations and lifting various payloads. The neural network was successfully trained in less time using standard parameters from PyTorch, ADAM optimizer, the various sensor inputs, and minimal output data. The SLIDE-trained neural network accelerated deflection estimation solutions by a factor of 10^7 in reference to flexible multibody simulation batches and provided reasonable accuracy. These results support the studies goal of providing robust, real-time solutions for control, robotic manipulators, structural health monitoring, and automation problems.

  • 6 authors
·
Mar 10, 2025

BrickSim: A Physics-Based Simulator for Manipulating Interlocking Brick Assemblies

Interlocking brick assemblies provide a standardized yet challenging testbed for contact-rich and long-horizon robotic manipulation, but existing rigid-body simulators do not faithfully capture snap-fit mechanics. We present BrickSim, the first real-time physics-based simulator for interlocking brick assemblies. BrickSim introduces a compact force-based mechanics model for snap-fit connections and solves the resulting internal force distribution using a structured convex quadratic program. Combined with a hybrid architecture that delegates rigid-body dynamics to the underlying physics engine while handling snap-fit mechanics separately, BrickSim enables real-time, high-fidelity simulation of assembly, disassembly, and structural collapse. On 150 real-world assemblies, BrickSim achieves 100% accuracy in static stability prediction with an average solve time of 5 ms. In dynamic drop tests, it also faithfully reproduces real-world structural collapse, precisely mirroring both the occurrence of breakage and the specific breakage locations. Built on Isaac Sim, BrickSim further supports seamless integration with a wide variety of robots and existing pipelines. We demonstrate robotic construction of brick assemblies using BrickSim, highlighting its potential as a foundation for research in dexterous, long-horizon robotic manipulation. BrickSim is open-source, and the code is available at https://github.com/intelligent-control-lab/BrickSim.

A Nonintrusive Distributed Reduced Order Modeling Framework for nonlinear structural mechanics -- application to elastoviscoplastic computations

In this work, we propose a framework that constructs reduced order models for nonlinear structural mechanics in a nonintrusive fashion, and can handle large scale simulations. We identify three steps that are carried out separately in time, and possibly on different devices: (i) the production of high-fidelity solutions by a commercial software, (ii) the offline stage of the model reduction and (iii) the online stage where the reduced order model is exploited. The nonintrusivity assumes that only the displacement field solution is known, and relies on operations on simulation data during the offline phase by using an in-house code. The compatibility with a new commercial code only needs the implementation of a routine converting the mesh and result format into our in-house data format. The nonintrusive capabilities of the framework are demonstrated on numerical experiments using commercial versions of the finite element softwares Zset and Ansys Mechanical. The nonlinear constitutive equations are evaluated by using the same external plugins as for Zset or Ansys Mechanical. The large scale simulations are handled using domain decomposition and parallel computing with distributed memory. The features and performances of the framework are evaluated on two numerical applications involving elastoviscoplastic materials: the second one involves a model of high-pressure blade, where the framework is used to extrapolate cyclic loadings in 6.5 hours, whereas the reference high-fidelity computation would take 9.5 days.

  • 5 authors
·
Dec 18, 2018

Integrating Large Language Models for Automated Structural Analysis

Automated analysis for engineering structures offers considerable potential for boosting efficiency by minimizing repetitive tasks. Although AI-driven methods are increasingly common, no systematic framework yet leverages Large Language Models (LLMs) for automatic structural analysis. To address this gap, we propose a novel framework that integrates LLMs with structural analysis software. LLMs serve as the core engine: they parse structural descriptions from text and translate them into executable Python scripts. Moreover, the framework integrates the generative capabilities of LLMs with code-based finite element (FE) tools like OpenSeesPy. It employs domain-specific prompt design and in-context learning strategies to enhance the LLM's problem-solving capabilities and generative stability, enabling fully automated structural analysis from descriptive text to model outputs. In our experiments, we introduce a well-curated small-scale benchmark dataset of 20 structural analysis word problems (SAWPs) with ground-truth solutions and evaluate the performance of different LLMs within our framework in solving these SAWPs. The role of system instructions, crafted by structural engineers, is also investigated to understand their impact on LLM-driven structural analysis. Additionally, the generative stability of our framework is examined. Through multiple validation experiments on the benchmark, our results demonstrate that the proposed framework can substantially increase the level of automation in solving SAWPs compared to traditional methods. Quantitatively, the framework, built on GPT-4o, achieved 100% accuracy, surpassing GPT-4 (85%), Gemini 1.5 Pro (80%), and Llama-3.3 (30%) on the test examples. Furthermore, integrating domain-specific instructions enhanced performance by 30% on problems with asymmetrical structural configurations.

  • 3 authors
·
Apr 13, 2025

DyFraNet: Forecasting and Backcasting Dynamic Fracture Mechanics in Space and Time Using a 2D-to-3D Deep Neural Network

The dynamics of materials failure is one of the most critical phenomena in a range of scientific and engineering fields, from healthcare to structural materials to transportation. In this paper we propose a specially designed deep neural network, DyFraNet, which can predict dynamic fracture behaviors by identifying a complete history of fracture propagation - from cracking onset, as a crack grows through the material, modeled as a series of frames evolving over time and dependent on each other. Furthermore, this model can not only forecast future fracture processes but also backcast to elucidate the past fracture history. In this scenario, once provided with the outcome of a fracture event, the model will elucidate past events that led to this state and will predict the future evolution of the failure process. By comparing the predicted results with atomistic-level simulations and theory, we show that DyFraNet can capture dynamic fracture mechanics by accurately predicting how cracks develop over time, including measures such as the crack speed, as well as when cracks become unstable. We use GradCAM to interpret how DyFraNet perceives the relationship between geometric conditions and fracture dynamics and we find DyFraNet pays special attention to the areas around crack tips, which have a critical influence in the early stage of fracture propagation. In later stages, the model pays increased attention to the existing or newly formed damage distribution in the material. The proposed approach offers significant potential to accelerate the exploration of the dynamics in material design against fracture failures and can be beneficially adapted for all kinds of dynamical engineering problems.

  • 2 authors
·
Nov 15, 2022

Unified Micromechanics Theory of Composites

We consider the matrix composite materials (CM) of either random (statistically homogeneous or inhomogeneous), periodic, or deterministic (neither random nor periodic) structures. CMs exhibit linear or nonlinear behavior, coupled or uncoupled multi-physical phenomena, locally elastic, weakly nonlocal (strain gradient and stress gradient), or strongly nonlocal (strain-type and displacement-type, peridynamics) phase properties. A modified Computational Analytical Micromechanics (CAM) approach introduces an exact Additive General Integral Equation (AGIE) for CMs of any structure and phase properties mentioned above. The unified iteration solution of static AGIEs is adapted to the body force with compact support serving as a fundamentally new universal training parameter. The approach also establishes a critical threshold for filtering out unsuitable sub-datasets of effective parameters through a novel Representative Volume Element (RVE) concept, which extends Hill's classical framework. This RVE concept eliminates sample size, boundary layer, and edge effects, making it applicable to CMs of any structure and phase properties, regardless of local or nonlocal, linear or nonlinear. Incorporating this new RVE concept into machine learning and neural network techniques enables the construction of any unpredefined surrogate nonlocal operators. The methodology is structured as a modular, block-based framework, allowing independent development and refinement of software components. This flexible, robust AGIE-CAM framework integrates data-driven, multi-scale, and multi-physics modeling, accelerating research in CM of any microtopology and phase properties considered. The AGIE-CAM framework represents a groundbreaking paradigm shift in the micromechanics of composites, redefining the very philosophy that underpins our understanding of their behavior at the microscopic level.

  • 1 authors
·
Mar 15, 2025

Simulating the Unseen: Crash Prediction Must Learn from What Did Not Happen

Traffic safety science has long been hindered by a fundamental data paradox: the crashes we most wish to prevent are precisely those events we rarely observe. Existing crash-frequency models and surrogate safety metrics rely heavily on sparse, noisy, and under-reported records, while even sophisticated, high-fidelity simulations undersample the long-tailed situations that trigger catastrophic outcomes such as fatalities. We argue that the path to achieving Vision Zero, i.e., the complete elimination of traffic fatalities and severe injuries, requires a paradigm shift from traditional crash-only learning to a new form of counterfactual safety learning: reasoning not only about what happened, but also about the vast set of plausible yet perilous scenarios that could have happened under slightly different circumstances. To operationalize this shift, our proposed agenda bridges macro to micro. Guided by crash-rate priors, generative scene engines, diverse driver models, and causal learning, near-miss events are synthesized and explained. A crash-focused digital twin testbed links micro scenes to macro patterns, while a multi-objective validator ensures that simulations maintain statistical realism. This pipeline transforms sparse crash data into rich signals for crash prediction, enabling the stress-testing of vehicles, roads, and policies before deployment. By learning from crashes that almost happened, we can shift traffic safety from reactive forensics to proactive prevention, advancing Vision Zero.

  • 15 authors
·
May 27, 2025

Learning Traffic Crashes as Language: Datasets, Benchmarks, and What-if Causal Analyses

The increasing rate of road accidents worldwide results not only in significant loss of life but also imposes billions financial burdens on societies. Current research in traffic crash frequency modeling and analysis has predominantly approached the problem as classification tasks, focusing mainly on learning-based classification or ensemble learning methods. These approaches often overlook the intricate relationships among the complex infrastructure, environmental, human and contextual factors related to traffic crashes and risky situations. In contrast, we initially propose a large-scale traffic crash language dataset, named CrashEvent, summarizing 19,340 real-world crash reports and incorporating infrastructure data, environmental and traffic textual and visual information in Washington State. Leveraging this rich dataset, we further formulate the crash event feature learning as a novel text reasoning problem and further fine-tune various large language models (LLMs) to predict detailed accident outcomes, such as crash types, severity and number of injuries, based on contextual and environmental factors. The proposed model, CrashLLM, distinguishes itself from existing solutions by leveraging the inherent text reasoning capabilities of LLMs to parse and learn from complex, unstructured data, thereby enabling a more nuanced analysis of contributing factors. Our experiments results shows that our LLM-based approach not only predicts the severity of accidents but also classifies different types of accidents and predicts injury outcomes, all with averaged F1 score boosted from 34.9% to 53.8%. Furthermore, CrashLLM can provide valuable insights for numerous open-world what-if situational-awareness traffic safety analyses with learned reasoning features, which existing models cannot offer. We make our benchmark, datasets, and model public available for further exploration.

  • 8 authors
·
Jun 15, 2024

MeLM, a generative pretrained language modeling framework that solves forward and inverse mechanics problems

We report a flexible multi-modal mechanics language model, MeLM, applied to solve various nonlinear forward and inverse problems, that can deal with a set of instructions, numbers and microstructure data. The framework is applied to various examples including bio-inspired hierarchical honeycomb design, carbon nanotube mechanics, and protein unfolding. In spite of the flexible nature of the model-which allows us to easily incorporate diverse materials, scales, and mechanical features-it performs well across disparate forward and inverse tasks. Based on an autoregressive attention-model, MeLM effectively represents a large multi-particle system consisting of hundreds of millions of neurons, where the interaction potentials are discovered through graph-forming self-attention mechanisms that are then used to identify relationships from emergent structures, while taking advantage of synergies discovered in the training data. We show that the model can solve complex degenerate mechanics design problems and determine novel material architectures across a range of hierarchical levels, providing an avenue for materials discovery and analysis. Looking beyond the demonstrations reported in this paper, we discuss other opportunities in applied mechanics and general considerations about the use of large language models in modeling, design, and analysis that can span a broad spectrum of material properties from mechanical, thermal, optical, to electronic.

  • 1 authors
·
Jun 30, 2023

Learning Nonlinear Responses in PET Bottle Buckling with a Hybrid DeepONet-Transolver Framework

Neural surrogates and operator networks for solving partial differential equation (PDE) problems have attracted significant research interest in recent years. However, most existing approaches are limited in their ability to generalize solutions across varying non-parametric geometric domains. In this work, we address this challenge in the context of Polyethylene Terephthalate (PET) bottle buckling analysis, a representative packaging design problem conventionally solved using computationally expensive finite element analysis (FEA). We introduce a hybrid DeepONet-Transolver framework that simultaneously predicts nodal displacement fields and the time evolution of reaction forces during top load compression. Our methodology is evaluated on two families of bottle geometries parameterized by two and four design variables. Training data is generated using nonlinear FEA simulations in Abaqus for 254 unique designs per family. The proposed framework achieves mean relative L^{2} errors of 2.5-13% for displacement fields and approximately 2.4% for time-dependent reaction forces for the four-parameter bottle family. Point-wise error analyses further show absolute displacement errors on the order of 10^{-4}-10^{-3}, with the largest discrepancies confined to localized geometric regions. Importantly, the model accurately captures key physical phenomena, such as buckling behavior, across diverse bottle geometries. These results highlight the potential of our framework as a scalable and computationally efficient surrogate, particularly for multi-task predictions in computational mechanics and applications requiring rapid design evaluation.

  • 5 authors
·
Sep 16, 2025

AccidentBench: Benchmarking Multimodal Understanding and Reasoning in Vehicle Accidents and Beyond

Rapid advances in multimodal models demand benchmarks that rigorously evaluate understanding and reasoning in safety-critical, dynamic real-world settings. We present AccidentBench, a large-scale benchmark that combines vehicle accident scenarios with Beyond domains, safety-critical settings in air and water that emphasize spatial and temporal reasoning (e.g., navigation, orientation, multi-vehicle motion). The benchmark contains approximately 2000 videos and over 19000 human-annotated question--answer pairs spanning multiple video lengths (short/medium/long) and difficulty levels (easy/medium/hard). Tasks systematically probe core capabilities: temporal, spatial, and intent understanding and reasoning. By unifying accident-centric traffic scenes with broader safety-critical scenarios in air and water, AccidentBench offers a comprehensive, physically grounded testbed for evaluating models under real-world variability. Evaluations of state-of-the-art models (e.g., Gemini-2.5 Pro and GPT-5) show that even the strongest models achieve only about 18% accuracy on the hardest tasks and longest videos, revealing substantial gaps in real-world temporal, spatial, and intent reasoning. AccidentBench is designed to expose these critical gaps and drive the development of multimodal models that are safer, more robust, and better aligned with real-world safety-critical challenges. The code and dataset are available at: https://github.com/SafeRL-Lab/AccidentBench

  • 12 authors
·
Sep 30, 2025

The Devil in the Details: Emergent Misalignment, Format and Coherence in Open-Weights LLMs

Prior work has shown that fine-tuning models on a narrow domain with misaligned data can lead to broad misalignment - a phenomenon termed "emergent misalignment" (Betley et al. 2025). While all tested models were susceptible to emergent misalignment, some models showed more resistance than others. Specifically the Qwen-2.5 family proved to be relatively resistant, while GPT-4o exhibited the strongest misalignment. In this paper we evaluate if current-generation open-weights models exhibit similar resistance to the Qwen-2.5 family and measure misalignment robustness over a range of model architectures and scales. We replicate the effect across nine modern open-weights models (Gemma 3 and Qwen 3 families, 1B-32B parameters). Models fine-tuned on insecure code generation show a 0.68% misalignment rate (compared to 0.07% for base models), matching the lower end of prior open-model results but dramatically lower than GPT-4o's 20%. We identify a critical format-dependent vulnerability: requiring JSON output doubles misalignment rates compared to natural language prompts (0.96% vs 0.42%). This suggests that structural constraints may bypass safety training by reducing the model's 'degrees of freedom' to refuse. These findings confirm emergent misalignment as a reproducible phenomenon in modern open-weights models, with rates substantially lower than observed in proprietary systems.

  • 1 authors
·
Nov 25, 2025

Learning Flexible Body Collision Dynamics with Hierarchical Contact Mesh Transformer

Recently, many mesh-based graph neural network (GNN) models have been proposed for modeling complex high-dimensional physical systems. Remarkable achievements have been made in significantly reducing the solving time compared to traditional numerical solvers. These methods are typically designed to i) reduce the computational cost in solving physical dynamics and/or ii) propose techniques to enhance the solution accuracy in fluid and rigid body dynamics. However, it remains under-explored whether they are effective in addressing the challenges of flexible body dynamics, where instantaneous collisions occur within a very short timeframe. In this paper, we present Hierarchical Contact Mesh Transformer (HCMT), which uses hierarchical mesh structures and can learn long-range dependencies (occurred by collisions) among spatially distant positions of a body -- two close positions in a higher-level mesh correspond to two distant positions in a lower-level mesh. HCMT enables long-range interactions, and the hierarchical mesh structure quickly propagates collision effects to faraway positions. To this end, it consists of a contact mesh Transformer and a hierarchical mesh Transformer (CMT and HMT, respectively). Lastly, we propose a flexible body dynamics dataset, consisting of trajectories that reflect experimental settings frequently used in the display industry for product designs. We also compare the performance of several baselines using well-known benchmark datasets. Our results show that HCMT provides significant performance improvements over existing methods. Our code is available at https://github.com/yuyudeep/hcmt.

  • 12 authors
·
Dec 19, 2023

Automating modeling in mechanics: LLMs as designers of physics-constrained neural networks for constitutive modeling of materials

Large language model (LLM)-based agentic frameworks increasingly adopt the paradigm of dynamically generating task-specific agents. We suggest that not only agents but also specialized software modules for scientific and engineering tasks can be generated on demand. We demonstrate this concept in the field of solid mechanics. There, so-called constitutive models are required to describe the relationship between mechanical stress and body deformation. Constitutive models are essential for both the scientific understanding and industrial application of materials. However, even recent data-driven methods of constitutive modeling, such as constitutive artificial neural networks (CANNs), still require substantial expert knowledge and human labor. We present a framework in which an LLM generates a CANN on demand, tailored to a given material class and dataset provided by the user. The framework covers LLM-based architecture selection, integration of physical constraints, and complete code generation. Evaluation on three benchmark problems demonstrates that LLM-generated CANNs achieve accuracy comparable to or greater than manually engineered counterparts, while also exhibiting reliable generalization to unseen loading scenarios and extrapolation to large deformations. These findings indicate that LLM-based generation of physics-constrained neural networks can substantially reduce the expertise required for constitutive modeling and represent a step toward practical end-to-end automation.

  • 7 authors
·
Dec 1, 2025