Multi-Scale Finite Element Simulation Framework for Deformation and Damage of Large Structure Under Complex Loadings

This paper establishes a multi-scale nested sub-modeling finite element simulation framework for the deformation and damage analysis of large-scale structures under complex loading conditions. By sequentially transferring displacement solutions from the global model to local sub-models, the framework enables progressive high-resolution analysis from the macroscopic scale (>10 m) down to the microscopic scale (~1 μm), thereby significantly improving solution accuracy in critical regions while maintaining computational efficiency. The proposed approach is validated on a shell structure subjected to hydrostatic pressure and on a plate with a central crack. The results show that the relative errors of stress and strain along specified paths in the shell structure are within 5%, while the relative errors of the stress intensity factor along the crack front in the cracked plate are also below 5%. Furthermore, the framework is integrated with the crystal plasticity finite element method, and a fatigue indicator parameter model based on the accumulated equivalent plastic strain is established to predict the shear fatigue life of Ti-6Al-4V ELI titanium alloy. The predicted fatigue lives are in good agreement with experimental data, with all errors below 10%. This study demonstrates that the proposed sub-modeling method can accurately transfer multi-scale mechanical responses and achieve localized refinement analysis of large-scale structures and can be effectively used for crystal plasticity simulations and fatigue life assessment.