Stochastic modeling of geometrical uncertainties on complex domains, with application to additive manufacturing and...

We present a stochastic modeling framework to represent and simulate spatially-dependent geometrical uncertainties on complex geometries. While the consideration of random geometrical perturbations has long been a subject of interest in computational engineering, most studies proposed so far have addressed the case of regular geometries such as cylinders and plates. Here, standard random field representations, such as Kahrunen-Loève expansions, can readily be used owing, in particular, to the relative simplicity to construct covariance operators on regular shapes. On the contrary, applying such techniques on arbitrary, non-convex domains remains difficult in general. In this work, we formulate a new representation for spatially-correlated geometrical uncertainties that allows complex domains to be efficiently handled. Building on previous contributions by the authors, the approach relies on the combination of a stochastic partial differential equation approach, introduced to capture salient features of the underlying geometry such as local curvature and singularities on the fly, and an information-theoretic model, aimed to enforce non-Gaussianity. More specifically, we propose a methodology where the interface of interest is immersed into a fictitious domain, and define algorithmic procedures to directly sample random perturbations on the manifold. A simple strategy based on statistical conditioning is also presented to update realizations and prevent self-intersections in the perturbed finite element mesh. We finally provide challenging examples to demonstrate the robustness of the framework, including the case of a gyroid structure produced by additive manufacturing and brain interfaces in patient-specific geometries. In both applications, we discuss suitable parameterization for the filtering operator and quantify the impact of the uncertainties through forward propagation.