Surrogate modelling for reliability assessment of cutting tools

Currently, cutting tool life for machining operations is correlated to process parameters through the widely applied Taylor functions. The latter are valuable expressions in established practice however their generalised nature does not allow accurate prediction of the tool’s service life or optimization of the manufacturing process due to effects of uncertainties in various input variables. These variables should be treated in a stochastic way in order to avoid employment of safety factors for quantification of uncertainty. This paper documents a procedure that allows derivation of analytical expressions for cutting tools performance employing advanced approximation methods and concepts of reliability analysis. Due to the complexity of manufacturing processes surrogate modelling (SM) methods are applied, starting from a few sample points obtained through lab or soft experiments and extending them to models able to predict/estimate the values of control values/indicators as a function of the key design variables, often referred to as limit states

The latent state hazard model, with application to wind turbine reliability

We present a new model for reliability analysis that is able to distinguish the latent internal vulnerability state of the equipment from the vulnerability caused by temporary external sources. Consider a wind farm where each turbine is running under the external effects of temperature, wind speed and direction, etc. The turbine might fail because of the external effects of a spike in temperature. If it does not fail during the temperature spike, it could still fail due to internal degradation, and the spike could cause (or be an indication of) this degradation. The ability to identify the underlying latent state can help better understand the effects of external sources and thus lead to more robust decision-making. We present an experimental study using SCADA sensor measurements from wind turbines in Italy.Comment: Published at http://dx.doi.org/10.1214/15-AOAS859 in the Annals of Applied Statistics (http://www.imstat.org/aoas/) by the Institute of Mathematical Statistics (http://www.imstat.org

Diagnostics of an Aircraft Engine Pumping Unit Using a Hybrid Approach based-on Surrogate Modeling

This document introduces a hybrid approach for fault detection and identification of an aircraft engine pumping unit. It is based on the complementarity between a model-based approach accounting for uncertainties aimed at quantifying the degradation modes signatures and a data-driven approach aimed at recalibrating the healthy syndrome from measures. Because of the computational time costs of uncertainties propagation into the physics based model, a surrogate modeling technic called Kriging associated to Latin hypercube sampling is utilized. The hybrid approach is tested on a pumping unit of an aircraft engine and shows good results for computing the degradation modes signatures and performing their detection and identification

Reliability assessment of cutting tool life based on surrogate approximation methods

A novel reliability estimation approach to the cutting tools based on advanced approximation methods is proposed. Methods such as the stochastic response surface and surrogate modeling are tested, starting from a few sample points obtained through fundamental experiments and extending them to models able to estimate the tool wear as a function of the key process parameters. Subsequently, different reliability analysis methods are employed such as Monte Carlo simulations and first- and second-order reliability methods. In the present study, these reliability analysis methods are assessed for estimating the reliability of cutting tools. The results show that the proposed method is an efficient method for assessing the reliability of the cutting tool based on the minimum number of experimental results. Experimental verification for the case of high-speed turning confirms the findings of the present study for cutting tools under flank wear

After-sales services optimisation through dynamic opportunistic maintenance: a wind energy case study

After-sales maintenance services can be a very profitable source of incomes for original equipment manufacturers (OEM) due to the increasing interest of assets’ users on performance-based contracts. However, when it concerns the product value-adding process, OEM have traditionally been more focused on improving their production processes, rather than on complementing their products by offering after-sales services; consequently leading to difficulties in offering them efficiently. Furthermore, both due to the high uncertainty of the assets’ behaviour and the inherent challenges of managing the maintenance process (e.g. maintenance strategy to be followed or resources to be deployed), it is complex to make business out of the provision of after-sales services. With the aim of helping the business and maintenance decision makers at this point, this paper proposes a framework for optimising the incomes of after-sales maintenance services through: 1) implementing advanced multi-objective opportunistic maintenance strategies that sistematically consider the assets’ operational context in order to perform preventive maintenance during most favourable conditions, 2) considering the specific OEMs’ and users’ needs, and 3) assessing both internal and external uncertainties that might condition the after-sales services’ success. The developed case study for the wind energy sector demonstrates the suitability of the presented framework for optimising the after-sales services.EU Framework Programme Horizon 2020, MSCA-RISE-2014: Marie Skłodowska-Curie Research and Innovation Staff Exchange (RISE) (grant agreement number 645733- Sustain-Owner-H2020-MSCA-RISE-2014) and the EmaitekPlus 2016-2017 Program of the Basque Government

Reliability-Based Optimum Inspection Planning for Components Subjected to Fatigue Induced Damage

The degradation of metallic systems under cyclic loading is prone to significant uncertainty. This uncertainty in turn affects the reliability in the prediction of residual lifetime and the subsequent decision regarding the optimum inspection and maintenance schedules. In particular, the experimental data on the evolution of fatigue-induced cracks shows significant scatter stemming from initial flaws, metallurgical heterogeneities, and randomness in material properties like yield stress and fracture toughness. The objective of this research is to improve the reliability-based optimal inspection planning of metallic systems subjected to fatigue, taking into account the associated uncertainty. To that end, this research aims to address the two main challenges faced in developing a credible reliability-based framework for lifecycle management of fatigue-critical components. The first challenge is to construct a stochastic model that can adequately capture the nonlinearity and uncertainty observed in the crack growth histories. The second one involves presenting a computationally efficient strategy for solving the stochastic optimization associated with optimum maintenance scheduling. In order to fulfill these objectives, a Polynomial Chaos (PC) representation is constructed of fatigue-induced crack growth process using a database from a constant amplitude loading experiment. The PC representation relies on expanding the crack growth stochastic process on a set of random basis functions whose coefficients are estimated from the experimental database. The probabilistic model obtained is then integrated into a reliability framework that minimizes the total expected life-cycle cost of the system subjected to constraints in terms of time to inspections, and the maximum probability of failure defined by the limit state function. Lastly, an efficient and accurate optimization strategy that uses surrogate models is suggested to solve the stochastic optimization problem. The sensitivity of the optimum solution to the level of risk is also examined. This research aims to provide a decision support tool for informed decision-making under uncertainty in the life-cycle planning of systems subjected to fatigue failure