Knowledge discovery for friction stir welding via data driven approaches: Part 2 – multiobjective modelling using fuzzy rule based systems

In this final part of this extensive study, a new systematic data-driven fuzzy modelling approach has been developed, taking into account both the modelling accuracy and its interpretability (transparency) as attributes. For the first time, a data-driven modelling framework has been proposed designed and implemented in order to model the intricate FSW behaviours relating to AA5083 aluminium alloy, consisting of the grain size, mechanical properties, as well as internal process properties. As a result, ‘Pareto-optimal’ predictive models have been successfully elicited which, through validations on real data for the aluminium alloy AA5083, have been shown to be accurate, transparent and generic despite the conservative number of data points used for model training and testing. Compared with analytically based methods, the proposed data-driven modelling approach provides a more effective way to construct prediction models for FSW when there is an apparent lack of fundamental process knowledge

Knowledge discovery for friction stir welding via data driven approaches: Part 1 – correlation analyses of internal process variables and weld quality

For a comprehensive understanding towards Friction Stir Welding (FSW) which would lead to a unified approach that embodies materials other than aluminium, such as titanium and steel, it is crucial to identify the intricate correlations between the controllable process conditions, the observable internal process variables, and the characterisations of the post-weld materials. In Part I of this paper, multiple correlation analyses techniques have been developed to detect new and previously unknown correlations between the internal process variables and weld quality of aluminium alloy AA5083. Furthermore, a new exploitable weld quality indicator has, for the first time, been successfully extracted, which can provide an accurate and reliable indication of the ‘as-welded’ defects. All results relating to this work have been validated using real data obtained from a series of welding trials that utilised a new revolutionary sensory platform called ARTEMIS developed by TWI Ltd., the original inventors of the FSW process

Model fusion using fuzzy aggregation: Special applications to metal properties

To improve the modelling performance, one should either propose a new modelling methodology or make the best of existing models. In this paper, the study is concentrated on the latter solution, where a structure-free modelling paradigm is proposed. It does not rely on a fixed structure and can combine various modelling techniques in ‘symbiosis’ using a ‘master fuzzy system’. This approach is shown to be able to include the advantages of different modelling techniques altogether by requiring less training and by minimising the efforts relating optimisation of the final structure. The proposed approach is then successfully applied to the industrial problems of predicting machining induced residual stresses for aerospace alloy components as well as modelling the mechanical properties of heat-treated alloy steels, both representing complex, non-linear and multi-dimensional environments

Multiobjective optimal design of friction stir welding considering quality and cost issues

Because of the high complexity in microstructure evolution in friction stir welding, it becomes very difficult to design optimal welding parameters. To solve this problem, in the current paper, soft computing based data driven models are developed to provide accurate and instant predictions for the welding process, and a multiobjective optimisation approach is employed to find optimal solutions to achieve the desired quality and economic objectives. The current work studies the aluminium AA5083-O as an example, where not only weld quality and mechanical properties of a joint but also in process properties and production cost are considered as objectives in the optimal design

A nature-inspired multi-objective optimisation strategy based on a new reduced space searching algorithm for the design of alloy steels

In this paper, a salient search and optimisation algorithm based on a new reduced space searching strategy, is presented. This algorithm originates from an idea which relates to a simple experience when humans search for an optimal solution to a ‘real-life’ problem, i.e. when humans search for a candidate solution given a certain objective, a large area tends to be scanned first; should one succeed in finding clues in relation to the predefined objective, then the search space is greatly reduced for a more detailed search. Furthermore, this new algorithm is extended to the multi-objective optimisation case. Simulation results of optimising some challenging benchmark problems suggest that both the proposed single objective and multi-objective optimisation algorithms outperform some of the other well-known Evolutionary Algorithms (EAs). The proposed algorithms are further applied successfully to the optimal design problem of alloy steels, which aims at determining the optimal heat treatment regime and the required weight percentages for chemical composites to obtain the desired mechanical properties of steel hence minimising production costs and achieving the overarching aim of ‘right-first-time production’ of metals

A new training method for leg explosive power in taekwondo and its data-driven predictive models

BACKGROUND: Kicking is the major way to score in a Taekwondo competition, which makes athletes’ leg power a key quality. However, the characteristics of leg power are very complex and it is difficult to generate physical models to predict training performance. OBJECTIVE: To study training programmes of leg power for Taekwondo using data-driven techniques in correlation analyses and modelling. METHODS: An 8-week program for training back squat training was performed using two devices, a Cormax training system and a conventional barbell. Data analysis was conducted to identify the factors affecting the explosive power training. Finally, a data-driven modelling paradigm employing fuzzy rule-based systems was developed to predict the training performance. RESULTS: The Cormax system performed better in improving athletes’ maximum power and velocity. Maximum leg power was best correlated with athletes’ height. The developed predictive models showed good accuracy despite possession of limited training data. CONCLUSIONS: This study demonstrated some new training devices which could greatly improve power training. Moreover, a state-of-the-art modelling strategy was able to construct accurate models for training and exercise performance. The predictive models will likely enhance the anticipation of training outcome in advance which may assist in formulating and improving the training programmes

Imprecise knowledge based design and development of titanium alloys for prosthetic applications

Imprecise knowledge on the composition–processing–microstructure–property correlation of titanium alloys combined with experimental data are used for developing rule based models for predicting the strength and elastic modulus of titanium alloys. The developed models are used for designing alloys suitable for orthopedic and dental applications. Reduced Space Searching Algorithm is employed for the multi-objective optimization to find composition, processing and microstructure of titanium alloys suitable for orthopedic applications. The conflicting requirements attributes of the alloys for this particular purpose are high strength with low elastic modulus, along with adequate biocompatibility and low costs. The ‘Pareto’ solutions developed through multi-objective optimization show that the preferred compositions for the fulfilling the above objectives lead to β or near β-alloys. The concept of decision making employed on the solutions leads to some compositions, which should provide better combination of the required attributes. The experimental development of some of the alloys has been carried out as guided by the model-based design methodology presented in this research. Primary characterizations of the alloys show encouraging results in terms of the mechanical properties

A new Reduced Space Searching Algorithm (RSSA) and its application in optimal design of alloy steels

In this paper, a new search and optimisation algorithm based on a reduced space searching strategy, named RSSA, is presented. This algorithm originates from an idea which relates to a simple experience when humans search for an optimal solution to a 'real-life' problem, i.e. when humans search for a candidate solution given a certain objective, a large area tends to be scanned first; should one succeed in finding clues in relation to the predefined objective, then the search space is greatly reduced for a more detailed search. The proposed algorithm is validated via well-known benchmark functions and is found to be efficient. Furthermore, the algorithm is extended to include the multiobjective case. Simulation results of optimising some challenging benchmark multiobjective problems, including the ZDT and DTLZ series problems, suggest that the new algorithm can locate the Pareto-optimal front and performs better than some other salient optimisation algorithms. Then, this proposed algorithm is successfully applied to the optimal design of alloy steels, which aims at determining the optimal heat treatment regimes and the required weight percentages for the chemical composites in order to obtain the pre-defined mechanical properties of the material