Michael Hohmann

Lisa Lüddecke, Michael Hohmann, Sebastian Eilermann et al.

Reliable prediction of hydraulic performance is challenging for Piano Key Weir (PKW) design because discharge capacity depends on three-dimensional geometry and operating conditions. Surrogate models can accelerate hydraulic-structure design, but progress is limited by scarce large, well-documented datasets that jointly capture geometric variation, operating conditions, and functional performance. This study presents WeirNet, a large 3D CFD benchmark dataset for geometric surrogate modeling of PKWs. WeirNet contains 3,794 parametric, feasibility-constrained rectangular and trapezoidal PKW geometries, each scheduled at 19 discharge conditions using a consistent free-surface OpenFOAM workflow, resulting in 71,387 completed simulations that form the benchmark and with complete discharge coefficient labels. The dataset is released as multiple modalities compact parametric descriptors, watertight surface meshes and high-resolution point clouds together with standardized tasks and in-distribution and out-of-distribution splits. Representative surrogate families are benchmarked for discharge coefficient prediction. Tree-based regressors on parametric descriptors achieve the best overall accuracy, while point- and mesh-based models remain competitive and offer parameterization-agnostic inference. All surrogates evaluate in milliseconds per sample, providing orders-of-magnitude speedups over CFD runtimes. Out-of-distribution results identify geometry shift as the dominant failure mode compared to unseen discharge values, and data-efficiency experiments show diminishing returns beyond roughly 60% of the training data. By publicly releasing the dataset together with simulation setups and evaluation pipelines, WeirNet establishes a reproducible framework for data-driven hydraulic modeling and enables faster exploration of PKW designs during the early stages of hydraulic planning.

Willi Grossmann, Sebastian Eilermann, Tim Rensmeyer et al.

Traditional design cycles for new materials and assemblies have two fundamental drawbacks. The underlying physical relationships are often too complex to be precisely calculated and described. Aside from that, many unknown uncertainties, such as exact manufacturing parameters or materials composition, dominate the real assembly behavior. Machine learning (ML) methods overcome these fundamental limitations through data-driven learning. In addition, modern approaches can specifically increase system knowledge. Representation Learning allows the physical, and if necessary, even symbolic interpretation of the learned solution. In this way, the most complex physical relationships can be considered and quickly described. Furthermore, generative ML approaches can synthesize possible morphologies of the materials based on defined conditions to visualize the effects of uncertainties. This modern approach accelerates the design process for new materials and enables the prediction and interpretation of realistic materials behavior.

C. Coelho, M. Hohmann, D. Fernández et al.

Thermal errors in machine tools significantly impact machining precision and productivity. Traditional thermal error correction/compensation methods rely on measured temperature-deformation fields or on transfer functions. Most existing data-driven compensation strategies employ neural networks (NNs) to directly predict thermal errors or specific compensation values. While effective, these approaches are tightly bound to particular error types, spatial locations, or machine configurations, limiting their generality and adaptability. In this work, we introduce a novel paradigm in which NNs are trained to predict high-fidelity temperature and heat flux fields within the machine tool. The proposed framework enables subsequent computation and correction of a wide range of error types using modular, swappable downstream components. The NN is trained using data obtained with the finite element method under varying initial conditions and incorporates a correlation-based selection strategy that identifies the most informative measurement points, minimising hardware requirements during inference. We further benchmark state-of-the-art time-series NN architectures, namely Recurrent NN, Gated Recurrent Unit, Long-Short Term Memory (LSTM), Bidirectional LSTM, Transformer, and Temporal Convolutional Network, by training both specialised models, tailored for specific initial conditions, and general models, capable of extrapolating to unseen scenarios. The results show accurate and low-cost prediction of temperature and heat flux fields, laying the basis for enabling flexible and generalisable thermal error correction in machine tool environments.