Digital Twin Multiphysics

Category: Analysis | Integrated 2026-04-06
CAE visualization for digital twin multiphysics theory - technical simulation diagram
Digital Twin Multiphysics

Digital Twin Multiphysics: Theoretical Foundations

Overview

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Teacher! Today's topic is about digital twin multiphysics, right? What is it?


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Real-time multiphysics model updating through assimilation with actual sensor data. Kalman filter. State estimation and prediction.




Governing Equations




$$ \mathbf{y} = h(\mathbf{x}) + \mathbf{v} $$
$$ \hat{\mathbf{x}}^+ = \hat{\mathbf{x}}^- + \mathbf{K}(\mathbf{y} - h(\hat{\mathbf{x}}^-)) $$



🧑‍🎓

So, if you cut corners on the "multi" part of the digital twin, you'll pay for it later. I'll keep that in mind!


Discretization Methods

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How do you actually solve these equations on a computer?


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We use spatial discretization by the Finite Element Method (FEM). We assemble the element stiffness matrix and construct the global stiffness equation.


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We perform transformation to the weak form (variational form) and use formulation by the Galerkin method using test functions and shape functions. The choice of element type (low-order elements vs. high-order elements, full integration vs. reduced integration) directly affects the trade-off between solution accuracy and computational cost.




Matrix Solution Algorithms

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What exactly are matrix solution algorithms?


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Solve the simultaneous equations by direct methods (LU decomposition, Cholesky decomposition) or iterative methods (CG method, GMRES method). Preconditioned iterative methods are effective for large-scale problems.



SolverClassificationMemory UsageApplicable Scale
LU decompositionDirect MethodO(n²)Small to Medium Scale
Cholesky decompositionDirect Method (Symmetric Positive Definite)O(n²)Small to Medium Scale
PCG MethodIterative MethodO(n)Large Scale
GMRES methodIterative MethodO(n·m)Large Scale / Non-symmetric
AMG PreconditionerPreprocessingO(n)Very Large Scale
🧑‍🎓

So, if you cut corners on the finite element method part, you'll pay for it later. I'll keep that in mind!


Implementation in Commercial Tools

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So, what software can be used to do digital twin multiphysics?


Tool NameDeveloper/CurrentMain File Format
COMSOL MultiphysicsCOMSOL AB.mph
Ansys Mechanical (formerly ANSYS Structural)Ansys Inc..cdb, .rst, .db, .ans, .mac
Abaqus FEA (SIMULIA)Dassault Systèmes SIMULIA.inp, .odb, .cae, .sta, .msg
Simcenter STAR-CCM+Siemens Digital Industries Software.sim, .java, .csv

Vendor Genealogy and Product Integration History

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Are the origins of each software quite dramatic?



COMSOL Multiphysics

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Tell me about "COMSOL Multiphysics"!


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Founded in Sweden in 1986. Started as FEMLAB with MATLAB integration, later renamed to COMSOL. Strong in multiphysics.

Current Affiliation: COMSOL AB



Ansys Mechanical (formerly ANSYS Structural)

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Tell me about "Ansys Mechanical"!


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Developed in 1970 by Swanson Analysis Systems Inc. (SASI). APDL (Ansys Parametric Design Language) based.

Current Affiliation: Ansys Inc.




Abaqus FEA (SIMULIA)

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What exactly is Abaqus FEA?


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Developed in 1978 by HKS (Hibbitt, Karlsson & Sorensen). Acquired by Dassault Systèmes in 2005 and integrated into the SIMULIA brand.

Current Affiliation: Dassault Systèmes SIMULIA


🧑‍🎓

Ah, I see! So that's how it was, founded in Sweden in '86.


File Formats and Interoperability

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Are there any points to note when transferring data between different software?


FormatExtensionTypeOverview
STEP.stp/.stepNeutral CAD3D CAD data exchange format compliant with ISO 10303. Supports geometry + PMI.
IGES.igs/.igesNeutral CADEarly CAD data exchange standard. Has issues with surface data compatibility. Transition to STEP is progressing.
VTK.vtk/.vtuVisualizationVisualization Toolkit format. Used by ParaView, etc.
MED.medMesh/ResultData exchange model format. Used by Code_Aster/Salome.
Related Simulators

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Related fields

Structural AnalysisElectromagnetic Field AnalysisThermal Analysis
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