Accurate Finite Element Model Research Articles

Developing an accurate finite element model for brake disc in contact with the pad using experimental modal analysis

The brake system is a critical safety component in cars, and its performance is essential for the safety of both the driver and passengers. The stability of the brake disc and understanding the contact area between the disc and the brake pads are crucial aspects of brake system design and performance. This paper aims to create an accurate model of the brake system, especially the contact area between the disc and the pads. This model can be used to investigate the effects of increasing braking pressure and changing the contact surface. Moreover, this model can calculate the dynamic responses of the system when an angular velocity is applied to the disc. First, a braking system was tested experimentally several times. Then a finite element model of the structure was created in ANSYS commercial software with defining suitable elements for the contact area between the disc and the pads. In the following, by an identification process a distribution of contact parameters at different braking pressures was obtained. The results shows that when the braking pressure increases, the dynamic responses of the structure increase, as well as the contact stiffness. A further increase in braking pressure does not have much effect on the contact stiffness and the contact area becomes like a new support.

Development of an FEM for the Combined Electromagnetic and Hydraulic Forming Process Based on Experimental Data

Electrohydraulic forming (EHF) which demonstrates reduced bouncing effect, formation in narrow areas, and no effect on the electrical conductivity of the blank can overcome the shortcomings of deep drawing and electromagnetic forming. However, considerable time is involved in evaluating the possibility of forming a specific part through experiments. Developing an accurate finite element model can reduce the opportunity costs of an experiment by reducing unnecessary trial and error in forming a specific part. In this study, the chamber, die, and blank components of the EHF experimental equipment in our laboratory were reverse-modeled using CATIA V5R18. Subsequently, the IGES format of the components was imported into LS-DYNA R12, and an FEM model to simulate the EHF experiment was constructed. The experimental and simulation results of nine cases, based on the SUS430 material, input voltage, and blank thickness, were compared for model verification. The forming results for all cases in the constructed finite element analysis model nearly matched the experimental results. Moreover, the linear increase in the blank thickness with input voltage and thickness was simultaneously confirmed. In a computing environment using a 4.3 GHz, 24-Core CPU and 64 GB memory, the time required for one finite element analysis was approximately 1 h.

Investigating the Morphology of a Free-Falling Jet with an Accurate Finite Element and Level Set Modeling

This study investigates the morphology of a free-falling liquid jet by using a computational approach with an experimental validation. Numerical simulations are developed by means of the Finite Element Method (FEM) for solving the viscous fluid flow and the level set method in order to track the interface between the fluid and air. Experiments are conducted in order to capture the shape of a free-falling jet of viscous fluid via circular orifice, where the shape is measured optically. The numerical results are found to be in agreement with the experimental data, demonstrating the validity of the proposed approach. Furthermore, we analyze the role of the surface tension by implementing linear as well as nonlinear surface energy models. All computational codes are developed with the aid of open-source packages from FEniCS and made publicly available. The combination of experimental and numerical techniques provides a comprehensive understanding of the morphology of free-falling jets and may be extended to multiphysics problems rather in a straightforward manner.

High-Efficiency Finite Element Model Updating of Bridge Structure Using a Novel Physics-Guided Neural Network

An accurate finite element model (FEM) plays a critical role in the structural damage identification. However, due to the existence of the uncertainties, such as material properties and modeling errors, it always exists some gaps between the analytical FEM and experimental structure. While an artificial neural network (ANN)-based model updating methods have been widely adopted to narrow the gap and obtain a baseline FEM, it still faces inaccurate results and fails to meet the physical law. In this regard, the study proposes a novel physics-based loss function inspired by modal sensitivity analysis and incorporates it into the residual neural network, thereby forming a novel physics-guided neural network (PGNN) method. The mapping relationship between the input of structural responses and output of model updating variables is constrained to retain its physical meaning by guiding the training process instead of pure data association, which aims to improve the accuracy of the ANN-based method and achieve accurate and high-efficiency model updating. An experimental example of a continuous rigid frame bridge is adopted to verify the feasibility of the proposed method. Additionally, other common model updating methods, including moth-flame optimization and regularization method, are used to make a comparison. The noise-robustness of the proposed method is investigated as well. Compared to the existing method, the results illustrate that the proposed PGNN method can achieve better model updating and good noise-robustness under high uncertainties, which means the introduction of the physics-based loss function significantly enhances the parameters updating ability of the neural network. The proposed method exhibits high efficiency and promising potential for large-scale bridge structure model updating.

Simulation-based analysis of welding process parameters for TC4ELI titanium alloy thick-walled cylinders

Abstract In this paper, ABAQUS is used to numerically simulate the residual stresses during welding of titanium alloy thick-walled cylinders. A detailed simulation analysis of the stress field during the welding process is performed by establishing an accurate finite element model, defining the thermal physical properties, boundary conditions, and heat source model, and using the indirect heat-force coupling method. The results of the study show that the distribution of the weld stress field has an important influence on weld quality, material properties, and structural strength. The movement of the welding heat source results in a dynamic change in the stress field, which gives rise to a significant stress concentration at and in the vicinity of the welding heat source.

Prediction Method for Mechanical Characteristic Parameters of Weak Components of 110 kV Transmission Tower under Ice-Covered Condition Based on Finite Element Simulation and Machine Learning

Icing on transmission lines may cause damage to tower components and even lead to structural failure. Aiming at the lack of research on predicting mechanical characteristic parameters of weak components of transmission towers, and the cumbersome steps of building a finite element model (FEM), the study of prediction for mechanical characteristic parameters of weak components of towers based on a finite element simulation and machine learning is proposed. Firstly, a 110 kV transmission tower in a heavily iced area is taken as an example to establish its FEM. The locations of the weak components are analyzed, and the accuracy of FEM is verified. Secondly, meteorological and terrain parameters are considered as input parameters of the prediction model. The axial stresses and nodal displacements of four weak components are selected as output parameters. The FEM of the 110 kV transmission tower is used to obtain input and output datasets. Thirdly, five machine learning algorithms are considered to establish the prediction models for mechanical characteristic parameters of weak components, and the optimal prediction model is obtained. Finally, the accuracy of the prediction method is verified through an actual tower collapse case. The results show that ACO-BPNN is the optimal model that can accurately and quickly predict the mechanical characteristic parameters of the weak components of the transmission tower. This study can provide an early warning for the failure prediction of transmission towers in heavily iced areas, thus providing an important reference for their safe operation and maintenance.

A biomimetic chiral auxetic vertebral meta-shell

Abstract The work presents a novel thin-walled biomimetic auxetic meta-shell for patient-specific vertebral orthopedic implants. The proposed design stemmed from the concept of an intrinsically multiple curved auxetic meta-structure, which is created by folding a 2D bio-inspired chiral geometry according to the morphology of human vertebral cortical bones. Through a multi-view stereo Digital Image Correlation (DIC) system, we investigated the mechanical response of a bio-grade titanium (Ti6Al4V ELI) additively manufactured prototype of the meta-structure under compressive loadings. In addition, we analyzed the morphology of the prototype using a scanning electron microscopy (SEM) and an optical image dimension measurement system both before and after compressive tests. An accurate Finite Element model, which exactly reproduced the geometry of the 3D printed meta-shell, was implemented and calibrated against experimental results, obtaining a precise prediction tool of its mechanical response. The findings of this work demonstrate that the designed meta-shell shows a peculiar auxetic behavior, a targeted stiffness matching to that of human vertebral bone tissues and a higher global elastic strain capability compared to those of monolithic traditional vertebral body replacements.


Electrothermal coupling analysis of submarine cables

ABSTRACT With offshore wind power transmission engineering development, submarine cable laying plays an important role in energy supply. Deep-water heavy-current composite submarine cables generate heat during power transmission, which raises their temperature and impacts energy efficiency and mechanical properties. To address the issue of heat release affecting structural sections during cable operation, a structural temperature field calculation theory is introduced, establishing a method for calculating the temperature field of submarine cables.The IEC standard's equivalent thermal circuit method and COMSOL Multiphysics' electromagnetic, thermal coupling method were employed to assess the current carrying capacity at the insulation temperature. The finite element model's accuracy was confirmed by comparing manufacturer-provided parameters. Additionally, a 3D finite-element model of the cable was created to determine its tensile, bending, and torsional stiffness with and without the electric-heat-force field coupling.

Seismic performance of an innovative self-centering and repairable connection with SMA bolts in modular steel construction

Modular steel construction (MSC) is widely noticed and adopted in the building industry for its benefits of short construction period, low carbon emission, and great flexibility. The performance of inter-module connections, including the strength, toughness and ductility, is the focus of maintaining the load transfer mechanism and overall stability of modular structures. The structure with favorably designed connections can dissipate expected energy under cyclic loading with reduced structural damage. A self-centering and repairable connection (SRC) is herein proposed, with the benefits of a distinct load transmission path and easy assembly. Four full-size specimens were fabricated and tested under low-cycle loading, and the tested specimens were subsequently repaired by replacing angle cleats. The failure mode and bearing capacity of both SRC and repaired SRC specimens were investigated. Several seismic performance indices of the specimens, including hysteresis curves, strength and stiffness degradation, energy dissipation capacity, self-centering and repairable ability, were obtained. Furthermore, the performance of the SRC was comprehensively assessed according to Eurocode 3 Part 1–8, Chinese code GB 50011-2010, and American code AISC 341-16. In addition, an accurate finite element model (FEM) of the SRC was created and verified using experimental results. The developed FEM was used to investigate the effects of critical parameters, including angle cleat thickness and grade, vertical bolt diameter, and SMA bolt number and diameter, on the seismic performance of SRCs. Both experimental and FEM results show that only the replaceable angle cleats experienced the noticed plastic deformation for SRC specimens under cyclic loading, and SMA bolts provided the required self-centering force. It can be hence concluded that the proposed SRC can achieve the expected self-centering and recovery function.

An automated framework for material property calibration in loudspeaker simulation model

The shift to virtual meetings, online classes, and remote work has established a new norm, leading to a surge in the use of virtual communication platforms such as Zoom and Microsoft Teams. This shift has increased the demand for high-quality headsets and speakerphones, emphasizing the need for clear, superior audio quality. The process of calibrating material properties typically relies on repetitive simulations guided by experts' intuition, presenting challenges in establishing new Finite Element Models (FEMs) of loudspeakers, as it requires the repeated identification of material property values. We present a systematic framework for calibrating the mechanical material properties of loudspeaker drivers, a crucial prerequisite for developing accurate FEMs of loudspeakers. Specifically, we propose a statistically-driven approach to replace the conventional manual calibration process, which typically relies on multiple simulations guided by expert intuition. Efficient Global Optimization (EGO) is applied to address the expensive optimization problems of loudspeaker simulation. To tackle the curse of dimensionality, the objective function is decomposed into several functions based on effective parameter groups using Global Sensitivity Analysis (GSA) results. The parameters of the FEM are then calibrated to the reference data from the Lumped Parameter Model (LPM) using the decomposed-reduced objective function, providing the calibrated parameters for the loudspeaker simulation. By implementing this novel approach, even individuals without prior knowledge or experience in loudspeaker material properties can effectively and reliably obtain the necessary data for finite element modeling.

Seismic Performance of Corroded ECC-GFRP Spiral-Confined Reinforced-Concrete Column.

Preventing corrosion in the steel reinforcement of concrete structures is crucial for maintaining structural integrity and load-bearing capacity as it directly impacts the safety and lifespan of concrete structures. By preventing rebar corrosion, the durability and seismic performance of the structures can be significantly enhanced. This study investigates the hysteresis behavior of both corroded and non-corroded engineered cementitious composite (ECC)-glass-fiber-reinforced polymer (GFRP) spiral-confined reinforced-concrete (RC) columns. Employing experimental methods and finite element analysis, this research explores key seismic parameters such as crack patterns, failure modes, hysteretic responses, load-bearing capacities, ductility, stiffness degradation, and energy dissipation. The results demonstrate that ECC-GFRP spiral-confined RC columns, compared to traditional RC columns, show reduced corrosion rates, smaller crack widths, and fewer corrosion products, indicating superior crack control and corrosion resistance. Hysteresis tests revealed that ECC-GFRP columns, at a 20% target corrosion rate, exhibit an enhanced load-bearing capacity, ductility, and energy dissipation, suggesting improved durability and seismic resilience. Parametric and sensitivity analyses confirm the finite element model's accuracy and highlight the significant influence of concrete compressive strength on load-bearing capacity. The findings suggest that ECC-GFRP spiral-confined RC columns offer promising applications in coastal and seismic-prone regions, enhancing corrosion resistance and mechanical properties, thus potentially reducing formwork costs and improving construction quality and efficiency.

Об одной новой схеме применения метода конечных элементов в горных науках

At the moment a large number of research papers are being published in the field of mining sciences, utilizing FEM (finite element method) in one way or another. The vast majority of these papers are devoted to solving various engineering problems in mining using different software products such as ABAQUS, PLAXIS, etc. It has been determined that almost all existing works in this field follow the typical scheme for the application of FEM. Materials and methods. The analysis showed that the typical scheme for the application of FEM in mining sciences contains a fundamental error related to the inadequate consideration of the representative volume of rocks during the construction of a continuous medium model and the formation of a discrete model. This leads to a significant degree of inaccuracy in the modeling results. Results and discussion. To resolve the fundamental error, a new scheme for the application of FEM in mining sciences is proposed. It differs from the typical scheme by introducing a new intermediate model between the rock mass and the continuum model. This model, named ‘rock mass body’, represents a set of geoparticles. The sizes of the geoparticles are determined according to the representative volume of the structural or textural components of the rock mass. Comparative analysis has shown that, unlike the typical scheme for the application of FEM, the use of the proposed scheme allows to get solutions with a high degree of accuracy when researching rocks with coarse-grained and medium-grained structures. Conclusion. An analysis of the typical scheme for the application of FEM identified a fundamental error in its use for rock mass modeling tasks. A new scheme has been proposed to correct this error. Suggestions for practical application and direction of future research. The research results can be used to improve the accuracy of finite element models of rock masses. Further research should focus on improving methods for determining the shape of finite elements in relation to the symmetry of the structural and textural components of the rock mass. At the same time, it is necessary to take into account the fracturing of rocks.

Comparative FEM study on intervertebral disc modeling: Holzapfel-Gasser-Ogden vs. structural rebars.

Introduction: Numerical modeling of the intervertebral disc (IVD) is challenging due to its complex and heterogeneous structure, requiring careful selection of constitutive models and material properties. A critical aspect of such modeling is the representation of annulus fibers, which significantly impact IVD biomechanics. This study presents a comparative analysis of different methods for fiber reinforcement in the annulus fibrosus of a finite element (FE) model of the human IVD. Methods: We utilized a reconstructed L4-L5 IVD geometry to compare three fiber modeling approaches: the anisotropic Holzapfel-Gasser-Ogden (HGO) model (HGO fiber model) and two sets of structural rebar elements with linear-elastic (linear rebar model) and hyperelastic (nonlinear rebar model) material definitions, respectively. Prior to calibration, we conducted a sensitivity analysis to identify the most important model parameters to be calibrated and improve the efficiency of the calibration. Calibration was performed using a genetic algorithm and in vitro range of motion (RoM) data from a published study with eight specimens tested under four loading scenarios. For validation, intradiscal pressure (IDP) measurements from the same study were used, along with additional RoM data from a separate publication involving five specimens subjected to four different loading conditions. Results: The sensitivity analysis revealed that most parameters, except for the Poisson ratio of the annulus fibers and C01 from the nucleus, significantly affected the RoM and IDP outcomes. Upon calibration, the HGO fiber model demonstrated the highest accuracy (R2 = 0.95), followed by the linear (R2 = 0.89) and nonlinear rebar models (R2 = 0.87). During the validation phase, the HGO fiber model maintained its high accuracy (RoM R2 = 0.85; IDP R2 = 0.87), while the linear and nonlinear rebar models had lower validation scores (RoM R2 = 0.71 and 0.69; IDP R2 = 0.86 and 0.8, respectively). Discussion: The results of the study demonstrate a successful calibration process that established good agreement with experimental data. Based on our findings, the HGO fiber model appears to be a more suitable option for accurate IVD FE modeling considering its higher fidelity in simulation results and computational efficiency.

Experimental and numerical analysis on the post-fire flexural behavior of aluminum alloy gusset joints

Regarding the damage incurred by aluminum alloy latticed shells under fire loads, a crucial aspect in assessing structural integrity is examining the residual bearing capacity of aluminum alloy gusset (AAG) joints. Consequently, this paper conducted experimental and numerical analyses on the post-fire flexural behavior of AAG joints. Initially, twelve AAG joints underwent post-fire tests, revealing that the failure patterns differed between thin-plate joints (exhibiting block tearing of gusset plates) and thick-plate joints (exhibiting member buckling). Notably, the initial stiffness approximately remained constant, while a trilinear relationship emerged between the ultimate flexural bearing capacity and the maximum post-fire temperature. Subsequently, finite element (FE) analysis was carried out, and the accuracy of FE models was verified by comparing the FE results with the test results. A comprehensive parametric analysis, considering various plate thicknesses, post-fire temperatures, and aluminum alloy brands, was then conducted. Ultimately, employing statistical regression, theoretical equations were formulated to estimate both bending stiffness and bearing capacity for AAG joints after exposure to fire.

Experimental and numerical analysis of assembled steel beam to CFDST column joint

A novel assembled joint between the concrete-filled double-skin steel tubular (CFDST) column and steel beams is developed in this paper. The joint is connected by extended endplates and high-strength bolts, and it is designed to facilitate post-disaster repairs. The pseudo-static test was performed on four 1:2 scaled joints, the endplate thickness, column form, and inner tube configuration were considered. The experimental results suggested excellent seismic performance of the joints, including plump hysteretic curves, high displacement ductility coefficients, and significant energy dissipation values. Then, accurate finite element (FE) models were established. Comparative results showed that the FE models better simulated the failure modes of endplate bending, weld tearing, local buckling of the flanges, and bolt fracture. In addition, there was a small deviation between the lateral load-bearing capacity obtained from tests and FE simulations. Next, stress analyses showed that the joint's yielding mode is from the flanges and endplates yielding to the outer tube web yielding. The stress on the inner tube was always lower than the yield stress, indicating that the CFDST column had a significant reserve of lateral load-bearing capacity. The main findings of numerous numerical analyses were that higher-strength endplates and steel beams with wider flanges substantially increased the lateral load-bearing capacity of the joint. Finally, a proposal was made to enhance the installation of ribs at beam ends. It improved the load-bearing capacity and initial stiffness and alleviated the stress concentration.

Model updating of a shear‐wall tall building using various vibration monitoring data: Accuracy and robustness

SummaryAcceleration measurements are often used for model updating of civil engineering structures, especially in the case of seismic monitoring. It is yet unclear if accelerations alone would generate an accurate and robust finite‐element (FE) model. This study examines this notion and analyzes the possibility of using other vibration monitoring data for model updating of shear‐wall tall buildings. This study compares the accuracy and robustness of the FE models being optimized via accelerations, roof displacement, wall rotations, interstory drift ratios, and the linear combination of these measurements. A numerical case study is analyzed using Timoshenko beams for modeling the lateral vibration of a benchmark 42‐story building under seismic excitations. Results show that the acceleration response of the examined building is mostly governed by its higher vibration modes. Depending on the characteristics of ground motions, using accelerations alone may generate an FE model biased towards higher‐order modes without effectively capturing the lower‐order modes. For instance, the first modal frequency of the updated FE model could be 12.0% lower than the true value, and the reconstructed displacement and rotation responses are noticeably inaccurate. Employing multi‐source monitoring data for model updating, for example, the combinations of roof displacement and acceleration measurements, could reduce the normalized root‐mean‐square errors in displacements by more than 70%. This study also quantifies the robustness of the FE model under various measurement noise levels and 50 pairs of earthquake records. Finally, the effects of multi‐source data on FE model updating are validated via experiments on a 7‐story shear wall building. Analysis reveals that a more accurate and robust FE model can be determined via a combination of accelerations and top displacement than via acceleration alone.

Experimental and numerical investigation on out-of-plane ultimate strength of high-strength steel arches

This study presents an experimental investigation on the out-of-plane ultimate strength of high-strength-steel (HSS) I-section arches, which has not been reported previously. Fourteen I-section HSS arches having different yield strengths, cross-sectional dimensions, slendernesses, and rise to span ratios were tested under three-point symmetrical vertical loading. The corresponding out-of-plane deformation modes and strengths are identified. Subsequently, in order to predict the out-of-plane capacities of HSS arches, a finite element analyses is carried out, which takes into consideration residual stresses and initial geometrical imperfections. This analysis demonstrates a strong alignment with the experimental results, confirming the accuracy of finite element model and experimental results. Furthermore, the study comprehensively analyzes the influence of yield strength of steel, rise-span ratio, and slenderness on the ultimate bearing capacity of HSS arches. Through a parametric analysis, design formulas for the out-of-plane bearing capacity of HSS arches subjected to arbitrary compression forces combined with arbitrary bending moments are formulated. It is found that the out-of-plane ultimate strength of HSS arches is significantly influenced by the yield strength of the steel. Compared to a low strength steel (LSS) arch, the out-of-plane ultimate bearing capacity of the HSS arch increases with an increase in yield strength in the plastic stage, and the ultimate lateral displacement of the HSS arch decreases with an increase in yield steel strength due to the lower ductility of HSS. In addition, after reaching the out-of-plane ultimate bearing load of arch, the load-displacement curve of the HSS arch drops faster than the LSS arch. It is also found that the proposed design formulas can effectively predict the out-of-plane bearing capacity of HSS arches.

The Development of a 3D-Printed Compliant System for the Orientation of Payloads on Small Satellites: Material Characterization and Finite Element Analysis of 3D-Printed Polyetherketoneketone (PEKK)

This article focuses on the development of a 3D-printed 2-degree-of-freedom (DOF) joint for the payloads’ orientation on small satellites. This system is a compliant mechanism, meaning that this monolithic system composed of cross-axis flexural pivots (CAFPs) produces complex movements through the elastic deformation of its structure. Using fused filament fabrication (FFF), a demonstrator made of Polyetherketoneketone (PEKK) is printed to determine its potential compatibility with space conditions. Focusing on a segment of the joint, the CAFP, this study aims for an enhancement of its mechanical behavior through the study of its printing direction and the creation of an accurate finite element model of this compliant mechanism. First, material characterization of 3D-printed PEKK is achieved through differential scanning calorimetry tests of the filament and flexural and tensile tests of specimens printed in different printing directions. Then, these data are used to perform a finite element analysis of different CAFP designs and compare their mechanical response of their 3D-printed twin using digital image correlation software. Finally, the CAFP structures were observed by X-ray tomography. The results show that printing direction greatly influences both flexural and tensile strength. Voids induced by the FFF process could impact the mechanical behavior of 3D-printed parts as the simple CAFP design has a better test/model correlation than complex ones. This could influence its resistance to space environment.

Segment selection for fusion and artificial disc replacement in the hybrid surgical treatment of noncontiguous cervical spondylosis: a finite element analysis.

Introduction: The treatment of skip-level cervical degenerative disease (CDD) with no degenerative changes observed in the intervening segment (IS) is complicated. This research aims to provide a reference basis for selecting treatment approaches for noncontiguous CDD. Methods: To establish accurate finite element models (FEMs), this study included computed tomography (CT) data from 21 patients with CDD (10 males and 11 females) for modeling. The study primarily discusses four cross-segment surgical approaches: upper (C3/4) anterior cervical discectomy and fusion (ACDF) and lower (C5/6) cervical disc arthroplasty (CDA), FA model; upper CDA (C3/4) and lower ACDF (C5/6), AF model; upper ACDF (C3/4) and lower ACDF (C5/6), FF model; upper CDA (C3/4) and lower CDA (C5/6), AA model. An initial axial load of 73.6 N was applied at the motion center using the follower load technique. A moment of 1.0Nm was applied at the center of the C2 vertebra to simulate the overall motion of the model. The statistical analysis was conducted using STATA version 14.0. Statistical significance was defined as a p value less than 0.05. Results: The AA group had significantly greater ROM in flexion and axial rotation in other segments compared to the FA group (p < 0.05). The FA group consistently exhibited higher average intervertebral disc pressure in C2/3 during all motions compared to the AF group (p < 0.001); however, the FA group displayed lower average intervertebral disc pressure in C6/7 during all motions (p < 0.05). The AA group had lower facet joint contact stresses during extension in all segments compared to the AF group (p < 0.05). The FA group exhibited significantly higher facet joint contact stresses during extension in C2/3 (p < 0.001) and C6/7 (p < 0.001) compared to the AF group. Discussion: The use of skip-level CDA is recommended for the treatment of non-contiguous CDD. The FA construct shows superior biomechanical performance compared to the AF construct.

A novel systematic approach for robust numerical simulation of carbon fiber-reinforced plastic circular tubes: Utilizing machine-learning techniques for calibration and validation

Developing a reliable and robust finite element model of a carbon fiber-reinforced plastic (CFRP) composite structure is investigated by using the LS-DYNA solver and Python. This study tries to provide a systematic numerical approach to cover the principal impediment to adaptation of composite energy absorbers, that is the lack of a reliable predictive method. The proposed procedure aims to further the understanding of advanced composite structures’ behavior during the crash phenomenon by developing an accurate finite element model. To do so, the mechanical properties of the material were extracted from American Society for Testing and Materials (ASTM) standard test methods, followed by experimental investigation of circular CFRP tubes undergoing quasi-static loading. A numerical simulation framework was then utilized to scrutinize the effectiveness of simulation parameters on the crushing mechanism. Finally, a systematic approach based on machine learning techniques was performed to adjust non-physical modeling parameters for further calibration and validation. In this regard, a versatile Python code was developed to automate pre-processing, processing, and post-processing steps. The code also provides a groundwork to perform machine learning techniques. Interestingly, the numerical and experimental results were highly correlated with a correlation coefficient of almost 90%. Additionally, several non-physical numerical parameters were found to be inactive, while some else were identified as effective parameters, and their corresponding effectiveness was quantitatively extracted and discussed for the first time in the literature.