OmniRemesh: Adaptive and Quasi-differentiable Remeshing for Crystal Plasticity Simulation and Inverse Parameter Calibration under Large Deformation

Abstract

Large-deformation crystal plasticity finite element method (CPFEM) simulations are often limited by accumulated mesh distortion, which degrades accuracy and numerical stability, while adaptive remeshing introduces discrete topology changes that impede gradient-based inverse analysis. We present OmniRemesh, a unified framework that addresses these forward and inverse challenges through two developments. First, a structure-driven remeshing method dynamically redistributes local mesh resolution according to both microstructural geometry and the evolving mechanical state. By refining grain boundaries and localized deformation regions while retaining a coarser mesh elsewhere, the method maintains mesh quality and physical consistency, improves the accuracy and robustness of large-deformation calculations, and resolves grain-scale heterogeneity without uniformly dense discretization. Second, a frozen-remeshing-branch strategy locally fixes the mesh sequence within a parameter trust region and periodically updates it as the parameters evolve. This treatment provides approximate automatic-differentiation sensitivities despite topology changes, enabling efficient inverse calibration of constitutive parameters against both macroscopic and local observables. Numerical examples demonstrate accurate and stable CPFEM simulations up to 80\% tensile deformation. The inverse calibration successfully recovers both macroscopic and local responses. OmniRemesh thus provides a practical framework for large-deformation CPFEM and remeshing-aware constitutive calibration.