ME Design and Freeform Fabrication of Compliant Cellular Materials with Graded Stiffness

Typically, cellular materials are designed for structural applications to provide stiffness or absorb impact via permanent plastic deformation. Alternatively, it is possible to design compliant cellular materials that absorb energy via recoverable elastic deformation, allowing the material to spring back to its original configuration after the load is released. Potential applications include automotive panels or prosthetic applications that require repeated, low-speed impact absorption without permanent deformation. The key is to arrange solid base material in cellular topologies that permit high levels of elastic deformation. To prevent plastic deformation, the topologies are designed for contact between cell walls at predetermined load levels, resulting in customized, graded stiffness profiles. Design techniques are established for synthesizing cellular topologies with customized compliance for static or quasi-static applications. The design techniques account for cell wall contact, large scale deformations, and material nonlinearities. Resulting cellular material designs are fabricated with selective laser sintering, and their properties are experimentally evaluated.Mechanical Engineerin

Solving optimisation problems in metal forming using Finite Element simulation and metamodelling techniques

During the last decades, Finite Element (FEM) simulations\ud of metal forming processes have become important\ud tools for designing feasible production processes. In more\ud recent years, several authors recognised the potential of\ud coupling FEM simulations to mathematical optimisation\ud algorithms to design optimal metal forming processes instead\ud of only feasible ones.\ud Within the current project, an optimisation strategy is being\ud developed, which is capable of optimising metal forming\ud processes in general using time consuming nonlinear\ud FEM simulations. The expression “optimisation strategy”\ud is used to emphasise that the focus is not solely on solving\ud optimisation problems by an optimisation algorithm, but\ud the way these optimisation problems in metal forming are\ud modelled is also investigated. This modelling comprises\ud the quantification of objective functions and constraints\ud and the selection of design variables.\ud This paper, however, is concerned with the choice for\ud and the implementation of an optimisation algorithm for\ud solving optimisation problems in metal forming. Several\ud groups of optimisation algorithms can be encountered in\ud metal forming literature: classical iterative, genetic and\ud approximate optimisation algorithms are already applied\ud in the field. We propose a metamodel based optimisation\ud algorithm belonging to the latter group, since approximate\ud algorithms are relatively efficient in case of time consuming\ud function evaluations such as the nonlinear FEM calculations\ud we are considering. Additionally, approximate optimisation\ud algorithms strive for a global optimum and do\ud not need sensitivities, which are quite difficult to obtain\ud for FEM simulations. A final advantage of approximate\ud optimisation algorithms is the process knowledge, which\ud can be gained by visualising metamodels.\ud In this paper, we propose a sequential approximate optimisation\ud algorithm, which incorporates both Response\ud Surface Methodology (RSM) and Design and Analysis\ud of Computer Experiments (DACE) metamodelling techniques.\ud RSM is based on fitting lower order polynomials\ud by least squares regression, whereas DACE uses Kriging\ud interpolation functions as metamodels. Most authors in\ud the field of metal forming use RSM, although this metamodelling\ud technique was originally developed for physical\ud experiments that are known to have a stochastic na-\ud ¤Faculty of Engineering Technology (Applied Mechanics group),\ud University of Twente, P.O. Box 217, 7500 AE, Enschede, The Netherlands,\ud email: [email protected]\ud ture due to measurement noise present. This measurement\ud noise is absent in case of deterministic computer experiments\ud such as FEM simulations. Hence, an interpolation\ud model fitted by DACE is thought to be more applicable in\ud combination with metal forming simulations. Nevertheless,\ud the proposed algorithm utilises both RSM and DACE\ud metamodelling techniques.\ud As a Design Of Experiments (DOE) strategy, a combination\ud of a maximin spacefilling Latin Hypercubes Design\ud and a full factorial design was implemented, which takes\ud into account explicit constraints. Additionally, the algorithm\ud incorporates cross validation as a metamodel validation\ud technique and uses a Sequential Quadratic Programming\ud algorithm for metamodel optimisation. To overcome\ud the problem of ending up in a local optimum, the\ud SQP algorithm is initialised from every DOE point, which\ud is very time efficient since evaluating the metamodels can\ud be done within a fraction of a second. The proposed algorithm\ud allows for sequential improvement of the metamodels\ud to obtain a more accurate optimum.\ud As an example case, the optimisation algorithm was applied\ud to obtain the optimised internal pressure and axial\ud feeding load paths to minimise wall thickness variations\ud in a simple hydroformed product. The results are satisfactory,\ud which shows the good applicability of metamodelling\ud techniques to optimise metal forming processes using\ud time consuming FEM simulations

A metamodel based optimisation algorithm for metal forming processes

Cost saving and product improvement have always been important goals in the metal\ud forming industry. To achieve these goals, metal forming processes need to be optimised. During\ud the last decades, simulation software based on the Finite Element Method (FEM) has significantly\ud contributed to designing feasible processes more easily. More recently, the possibility of\ud coupling FEM to mathematical optimisation algorithms is offering a very promising opportunity\ud to design optimal metal forming processes instead of only feasible ones. However, which\ud optimisation algorithm to use is still not clear.\ud In this paper, an optimisation algorithm based on metamodelling techniques is proposed\ud for optimising metal forming processes. The algorithm incorporates nonlinear FEM simulations\ud which can be very time consuming to execute. As an illustration of its capabilities, the\ud proposed algorithm is applied to optimise the internal pressure and axial feeding load paths\ud of a hydroforming process. The product formed by the optimised process outperforms products\ud produced by other, arbitrarily selected load paths. These results indicate the high potential of\ud the proposed algorithm for optimising metal forming processes using time consuming FEM\ud simulations

Restoration of the cantilever bowing distortion in Atomic Force Microscopy

Due to the mechanics of the Atomic Force Microscope (AFM), there is a curvature distortion (bowing effect) present in the acquired images. At present, flattening such images requires human intervention to manually segment object data from the background, which is time consuming and highly inaccurate. In this paper, an automated algorithm to flatten lines from AFM images is presented. The proposed method classifies the data into objects and background, and fits convex lines in an iterative fashion. Results on real images from DNA wrapped carbon nanotubes (DNACNTs) and synthetic experiments are presented, demonstrating the effectiveness of the proposed algorithm in increasing the resolution of the surface topography. In addition a link between the flattening problem and MRI inhomogeneity (shading) is given and the proposed method is compared to an entropy based MRI inhomogeniety correction method

Design and Implementation of Model Predictive Control Strategies for Improved Power Plant Cycling

Design and Implementation of Model Predictive Control Strategies for Improved Power Plant Cycling Xin He With the increasing focus on renewable energy sources, traditional power plants such as coal-fired power plants will have to cycle their load to accommodate the penetration of renewables into the power grid. Significant overshooting and oscillatory performance may occur during cycling operations if classical feedback control strategies are employed for plantwide control. To minimize the impact when power plants are operating away from their designed conditions, model-based optimal control strategies would need to be developed for improved power plant performance during cycling. In this thesis, model predictive control (MPC) strategies are designed and implemented for improved power plant cycling. The MPC strategies addressed correspond to a dynamic matrix control (DMC)-based linear MPC, a classical sequential quadratic programming (SQP)-based nonlinear MPC, a direct transcription-based nonlinear MPC and a proposed modified SQP-based nonlinear MPC. The proposed modified SQP algorithm is based on the backtracking line search framework, which employs a group of relaxed step acceptance conditions for faster convergence. The numerical results for motivating examples, which are selected from literature problem sets, served as proof of concept to verify that the proposed modified SQP has the potential for implementation on high-dimensional systems. To illustrate the tracking performance and computational efficiency of the developed MPC strategies, three processes of different dimensionalities are addressed. The first process is an integrated gasification combined cycling power plant with a water-gas shift membrane reactor (IGCC-MR), which is represented by a first-principles and simplified systems-level nonlinear model in MATLAB. For this application, a setpoint tracking scenario simulating a step increase in power demand, a disturbance rejection scenario simulating a coal feed quality change, and a trajectory tracking scenario simulating a wind power penetration into the power grid are presented. The second application is an aqueous monoethanolamine (MEA)-based carbon capture process as part of a supercritical pulverized coal-fired (SCPC) power plant, whose model is built in Aspen Plus Dynamics. For this system, disturbance rejection scenarios considering a ramp decrease in the flue gas flow rate as well as wind power penetration, and a scenario considering a combination of disturbance rejection and setpoint tracking are addressed. The third process is the entire SCPC power plant with MEA-based carbon capture (SCPC-MEA), which simulation is also built in Aspen Plus Dynamics. Trajectory tracking and disturbance rejection scenarios associated with wind and solar power penetrations are presented for this process. The MPC implementations on the three processes for the different scenarios addressed are successful. The closed-loop results show that the proposed modified SQP-based nonlinear MPC enhances the tracking performance by up to 96% when compared to the DMC-based linear MPC in terms of integral squared error results. The novel approach also improves the MPC computational efficiency by 20% when compared to classical SQP-based and direct transcription-based nonlinear MPCs

Adjoint methods for aerodynamic wing design

A model inverse design problem is used to investigate the effect of flow discontinuities on the optimization process. The optimization involves finding the cross-sectional area distribution of a duct that produces velocities that closely match a targeted velocity distribution. Quasi-one-dimensional flow theory is used, and the target is chosen to have a shock wave in its distribution. The objective function which quantifies the difference between the targeted and calculated velocity distributions may become non-smooth due to the interaction between the shock and the discretization of the flowfield. This paper offers two techniques to resolve the resulting problems for the optimization algorithms. The first, shock-fitting, involves careful integration of the objective function through the shock wave. The second, coordinate straining with shock penalty, uses a coordinate transformation to align the calculated shock with the target and then adds a penalty proportional to the square of the distance between the shocks. The techniques are tested using several popular sensitivity and optimization methods, including finite-differences, and direct and adjoint discrete sensitivity methods. Two optimization strategies, Gauss-Newton and sequential quadratic programming (SQP), are used to drive the objective function to a minimum