SQG-Differential Evolution for difficult optimization problems under a tight function evaluation budget

In the context of industrial engineering, it is important to integrate efficient computational optimization methods in the product development process. Some of the most challenging simulation-based engineering design optimization problems are characterized by: a large number of design variables, the absence of analytical gradients, highly non-linear objectives and a limited function evaluation budget. Although a huge variety of different optimization algorithms is available, the development and selection of efficient algorithms for problems with these industrial relevant characteristics, remains a challenge. In this communication, a hybrid variant of Differential Evolution (DE) is introduced which combines aspects of Stochastic Quasi-Gradient (SQG) methods within the framework of DE, in order to improve optimization efficiency on problems with the previously mentioned characteristics. The performance of the resulting derivative-free algorithm is compared with other state-of-the-art DE variants on 25 commonly used benchmark functions, under tight function evaluation budget constraints of 1000 evaluations. The experimental results indicate that the new algorithm performs excellent on the 'difficult' (high dimensional, multi-modal, inseparable) test functions. The operations used in the proposed mutation scheme, are computationally inexpensive, and can be easily implemented in existing differential evolution variants or other population-based optimization algorithms by a few lines of program code as an non-invasive optional setting. Besides the applicability of the presented algorithm by itself, the described concepts can serve as a useful and interesting addition to the algorithmic operators in the frameworks of heuristics and evolutionary optimization and computing

CFDNet: a deep learning-based accelerator for fluid simulations

CFD is widely used in physical system design and optimization, where it is used to predict engineering quantities of interest, such as the lift on a plane wing or the drag on a motor vehicle. However, many systems of interest are prohibitively expensive for design optimization, due to the expense of evaluating CFD simulations. To render the computation tractable, reduced-order or surrogate models are used to accelerate simulations while respecting the convergence constraints provided by the higher-fidelity solution. This paper introduces CFDNet -- a physical simulation and deep learning coupled framework, for accelerating the convergence of Reynolds Averaged Navier-Stokes simulations. CFDNet is designed to predict the primary physical properties of the fluid including velocity, pressure, and eddy viscosity using a single convolutional neural network at its core. We evaluate CFDNet on a variety of use-cases, both extrapolative and interpolative, where test geometries are observed/not-observed during training. Our results show that CFDNet meets the convergence constraints of the domain-specific physics solver while outperforming it by 1.9 - 7.4x on both steady laminar and turbulent flows. Moreover, we demonstrate the generalization capacity of CFDNet by testing its prediction on new geometries unseen during training. In this case, the approach meets the CFD convergence criterion while still providing significant speedups over traditional domain-only models.Comment: It has been accepted and almost published in the International Conference in Supercomputing (ICS) 202

Multi-Hierarchical Surrogate Learning for Structural Dynamical Crash Simulations Using Graph Convolutional Neural Networks

Crash simulations play an essential role in improving vehicle safety, design optimization, and injury risk estimation. Unfortunately, numerical solutions of such problems using state-of-the-art high-fidelity models require significant computational effort. Conventional data-driven surrogate modeling approaches create low-dimensional embeddings for evolving the dynamics in order to circumvent this computational effort. Most approaches directly operate on high-resolution data obtained from numerical discretization, which is both costly and complicated for mapping the flow of information over large spatial distances. Furthermore, working with a fixed resolution prevents the adaptation of surrogate models to environments with variable computing capacities, different visualization resolutions, and different accuracy requirements. We thus propose a multi-hierarchical framework for structurally creating a series of surrogate models for a kart frame, which is a good proxy for industrial-relevant crash simulations, at different levels of resolution. For multiscale phenomena, macroscale features are captured on a coarse surrogate, whereas microscale effects are resolved by finer ones. The learned behavior of the individual surrogates is passed from coarse to finer levels through transfer learning. In detail, we perform a mesh simplification on the kart model to obtain multi-resolution representations of it. We then train a graph-convolutional neural network-based surrogate that learns parameter-dependent low-dimensional latent dynamics on the coarsest representation. Subsequently, another, similarly structured surrogate is trained on the residual of the first surrogate using a finer resolution. This step can be repeated multiple times. By doing so, we construct multiple surrogates for the same system with varying hardware requirements and increasing accuracy

Topology Optimization Applications on Engineering Structures

Over the years, several optimization techniques were widely used to find the optimum shape and size of engineering structures (trusses, frames, etc.) under different constraints (stress, displacement, buckling instability, kinematic stability, and natural frequency). But, most of them require continuous data set where, on the other hand, topology optimization (TO) can handle also discrete ones. Topology optimization has also allowed radical changes in geometry which concludes better designs. So, many researchers have studied on topology optimization by developing/using different methodologies. This study aims to classify these studies considering used methods and present new emerging application areas. It is believed that researchers will easily find the related studies with their work

SOLID-SHELL FINITE ELEMENT MODELS FOR EXPLICIT SIMULATIONS OF CRACK PROPAGATION IN THIN STRUCTURES

Crack propagation in thin shell structures due to cutting is conveniently simulated using explicit finite element approaches, in view of the high nonlinearity of the problem. Solidshell elements are usually preferred for the discretization in the presence of complex material behavior and degradation phenomena such as delamination, since they allow for a correct representation of the thickness geometry. However, in solid-shell elements the small thickness leads to a very high maximum eigenfrequency, which imply very small stable time-steps. A new selective mass scaling technique is proposed to increase the time-step size without affecting accuracy. New ”directional” cohesive interface elements are used in conjunction with selective mass scaling to account for the interaction with a sharp blade in cutting processes of thin ductile shells

Computationally Efficient Concurrent Multiscale Framework for the Linear Analysis of Composite Structures

This paper presents a novel multiscale framework based on higher-order one-dimensional finite element models. The refined finite element models (FE) originate from the Carrera Unified Formulation (CUF), a novel and efficient methodology to develop higher-order structural theories hierarchically via a variable kinematic approach. The concurrent multiscale framework consists of a macroscale model to describe the structural level components interfaced with efficient CUF micromechanical models. Such micromechanical models can take into account the detailed architecture of the microstructure with high fidelity. The framework derives its efficiency from the capability of CUF models to detect accurate 3D-like stress fields at reduced computational costs. This paper also shows the ability of the framework to interface with different classes of representative volume elements (RVE) and the benefits of parallel implementations. The numerical cases focus on composite and sandwich structures and demonstrate the high-fidelity and feasibility of the proposed framework. The efficiency of the framework stems from comparisons with the analysis time and memory requirement against traditional multiscale implementations. The present paper is a companion of a linked work dealing with nonlinear material implementations

AI-based design methodologies for hot form quench (HFQ®)

This thesis aims to develop advanced design methodologies that fully exploit the capabilities of the Hot Form Quench (HFQ®) stamping process in stamping complex geometric features in high-strength aluminium alloy structural components. While previous research has focused on material models for FE simulations, these simulations are not suitable for early-phase design due to their high computational cost and expertise requirements. This project has two main objectives: first, to develop design guidelines for the early-stage design phase; and second, to create a machine learning-based platform that can optimise 3D geometries under hot stamping constraints, for both early and late-stage design. With these methodologies, the aim is to facilitate the incorporation of HFQ capabilities into component geometry design, enabling the full realisation of its benefits. To achieve the objectives of this project, two main efforts were undertaken. Firstly, the analysis of aluminium alloys for stamping deep corners was simplified by identifying the effects of corner geometry and material characteristics on post-form thinning distribution. New equation sets were proposed to model trends and design maps were created to guide component design at early stages. Secondly, a platform was developed to optimise 3D geometries for stamping, using deep learning technologies to incorporate manufacturing capabilities. This platform combined two neural networks: a geometry generator based on Signed Distance Functions (SDFs), and an image-based manufacturability surrogate model. The platform used gradient-based techniques to update the inputs to the geometry generator based on the surrogate model's manufacturability information. The effectiveness of the platform was demonstrated on two geometry classes, Corners and Bulkheads, with five case studies conducted to optimise under post-stamped thinning constraints. Results showed that the platform allowed for free morphing of complex geometries, leading to significant improvements in component quality. The research outcomes represent a significant contribution to the field of technologically advanced manufacturing methods and offer promising avenues for future research. The developed methodologies provide practical solutions for designers to identify optimal component geometries, ensuring manufacturing feasibility and reducing design development time and costs. The potential applications of these methodologies extend to real-world industrial settings and can significantly contribute to the continued advancement of the manufacturing sector.Open Acces

A review of the Discrete Element Method/Modelling (DEM) in agricultural engineering

With the development of high-performance computing technology, the number of scientific publications regarding computational modelling of applications with the Discrete Element Method/Modelling (DEM) approaches in agricultural engineering has risen in the past decades. Many granular materials, e.g. grains, fruits and soils in agricultural engineering are processed, and thus a better understanding of these granular media with DEM is of great significance in design and optimization of tools and process in agricultural engineering. In this review, the theory and background of DEM have been introduced. Some improved contact models discussed in the literature for accurately predicting the contact force between two interacting particles have been compared. Accurate approximation of irregular particle shapes is of great importance in DEM simulations to model real particles in agricultural engineering. New algorithms to approximate irregular particle shapes, e.g. overlapping multi-sphere approach, ellipsoid, etc. have been summarized. Some remarkable engineering applications of the improved numerical models developed and implemented in DEM are discussed. Finally, potential applications of DEM and some suggested further work are addressed in the last section of this review