Integrated modeling and analysis methodologies for architecture-level vehicle design.

In order to satisfy customer expectations, a ground vehicle must be designed to meet a broad range of performance requirements. A satisfactory vehicle design process implements a set of requirements reflecting necessary, but perhaps not sufficient conditions for assuring success in a highly competitive market. An optimal architecture-level vehicle design configuration is one of the most important of these requirements. A basic layout that is efficient and flexible permits significant reductions in the time needed to complete the product development cycle, with commensurate reductions in cost. Unfortunately, architecture-level design is the most abstract phase of the design process. The high-level concepts that characterize these designs do not lend themselves to traditional analyses normally used to characterize, assess, and optimize designs later in the development cycle. This research addresses the need for architecture-level design abstractions that can be used to support ground vehicle development. The work begins with a rigorous description of hierarchical function-based abstractions representing not the physical configuration of the elements of a vehicle, but their function within the design space. The hierarchical nature of the abstractions lends itself to object orientation - convenient for software implementation purposes - as well as description of components, assemblies, feature groupings based on non-structural interactions, and eventually, full vehicles. Unlike the traditional early-design abstractions, the completeness of our function-based hierarchical abstractions, including their interactions, allows their use as a starting point for the derivation of analysis models. The scope of the research in this dissertation includes development of meshing algorithms for abstract structural models, a rigid-body analysis engine, and a fatigue analysis module. It is expected that the results obtained in this study will move systematic design and analysis to the earliest phases of the vehicle development process, leading to more highly optimized architectures, and eventually, better ground vehicles. This work shows that architecture level abstractions in many cases are better suited for life cycle support than geometric CAD models. Finally, substituting modeling, simulation, and optimization for intuition and guesswork will do much to mitigate the risk inherent in large projects by minimizing the possibility of incorporating irrevocably compromised architecture elements into a vehicle design that no amount of detail-level reengineering can undo

Automatic constraint-based synthesis of non-uniform rational B-spline surfaces

In this dissertation a technique for the synthesis of sculptured surface models subject to several constraints based on design and manufacturability requirements is presented. A design environment is specified as a collection of polyhedral models which represent components in the vicinity of the surface to be designed, or regions which the surface should avoid. Non-uniform rational B-splines (NURBS) are used for surface representation, and the control point locations are the design variables. For some problems the NURBS surface knots and/or weights are included as additional design variables. The primary functional constraint is a proximity metric which induces the surface to avoid a tolerance envelope around each component. Other functional constraints include: an area/arc-length constraint to counteract the expansion effect of the proximity constraint, orthogonality and parametric flow constraints (to maintain consistent surface topology and improve machinability of the surface), and local constraints on surface derivatives to exploit part symmetry. In addition, constraints based on surface curvatures may be incorporated to enhance machinability and induce the synthesis of developable surfaces;The surface synthesis problem is formulated as an optimization problem. Traditional optimization techniques such as quasi-Newton, Nelder-Mead simplex and conjugate gradient, yield only locally good surface models. Consequently, simulated annealing (SA), a global optimization technique is implemented. SA successfully synthesizes several highly multimodal surface models where the traditional optimization methods failed. Results indicate that this technique has potential applications as a conceptual design tool supporting concurrent product and process development methods

Designing aesthetically pleasing freeform surfaces in a computer environment

Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Architecture, February 2001.Includes bibliographical references (p. 151-160).Statement: If computational tools are to be employed in the aesthetic design of freeform surfaces, these tools must better reflect the ways in which creative designers conceive of and develop such shapes. In this thesis, I studied the design of aesthetically constrained freeform surfaces in architecture and industrial design, formulated a requirements list for a computational system that would aid in the creative design of such surfaces, and implemented a subset of the tools that would comprise such a system. This work documents the clay modeling process at BMW AG., Munich. The study of that process has led to a list of tools that would make freeform surface modeling possible in a computer environment. And finally, three tools from this system specification have been developed into a proof-of-concept system. Two of these tools are sweep modification tools and the third allows a user to modify a surface by sketching a shading pattern desired for the surface. The proof-of-concept tools were necessary in order to test the validity of the tools being presented and they have been used to create a number of example objects. The underlying surface representation is a variational expression which is minimized using the finite element method over an irregular triangulated mesh.by Evan P. Smyth.Ph.D

Development and Integration of Geometric and Optimization Algorithms for Packing and Layout Design

The research work presented in this dissertation focuses on the development and application of optimization and geometric algorithms to packing and layout optimization problems. As part of this research work, a compact packing algorithm, a physically-based shape morphing algorithm, and a general purpose constrained multi-objective optimization algorithm are proposed. The compact packing algorithm is designed to pack three-dimensional free-form objects with full rotational freedom inside an arbitrary enclosure such that the packing efficiency is maximized. The proposed compact packing algorithm can handle objects with holes or cavities and its performance does not degrade significantly with the increase in the complexity of the enclosure or the objects. It outputs the location and orientation of all the objects, the packing sequence, and the packed configuration at the end of the packing operation. An improved layout algorithm that works with arbitrary enclosure geometry is also proposed. Different layout algorithms for the SAE and ISO luggage are proposed that exploit the unique characteristics of the problem under consideration. Several heuristics to improve the performance of the packing algorithm are also proposed. The proposed compact packing algorithm is benchmarked on a wide variety of synthetic and hypothetical problems and is shown to outperform other similar approaches. The physically-based shape morphing algorithm proposed in this dissertation is specifically designed for packing and layout applications, and thus it augments the compact packing algorithm. The proposed shape morphing algorithm is based on a modified mass-spring system which is used to model the morphable object. The shape morphing algorithm mimics a quasi-physical process similar to the inflation/deflation of a balloon filled with air. The morphing algorithm starts with an initial manifold geometry and morphs it to obtain a desired volume such that the obtained geometry does not interfere with the objects surrounding it. Several modifications to the original mass-spring system and to the underlying physics that governs it are proposed to significantly speed-up the shape morphing process. Since the geometry of a morphable object continuously changes during the morphing process, most collision detection algorithms that assume the colliding objects to be rigid cannot be used efficiently. And therefore, a general-purpose surface collision detection algorithm is also proposed that works with deformable objects and does not require any preprocessing. Many industrial design problems such as packing and layout optimization are computationally expensive, and a faster optimization algorithm can reduce the number of iterations (function evaluations) required to find the satisfycing solutions. A new multi-objective optimization algorithm namely Archive-based Micro Genetic Algorithm (AMGA2) is presented in this dissertation. Improved formulation for various operators used by the AMGA2 such as diversity preservation techniques, genetic variation operators, and the selection mechanism are also proposed. The AMGA2 also borrows several concepts from mathematical sciences to improve its performance and benefits from the existing literature in evolutionary optimization. A comprehensive benchmarking and comparison of AMGA2 with other state-of-the-art optimization algorithms on a wide variety of mathematical problems gleaned from literature demonstrates the superior performance of AMGA2. Thus, the research work presented in this dissertation makes contributions to the development and application of optimization and geometric algorithms

Semi-automated approach to shape optimal design of planar structures

This paper presents a general algorithm, using IDEAS programmability features to integrate different phases of shape optimization process. The present work is mainly concentrated on planar structures, defined by thin or shell finite elements. Interactive programs are generated to convert input data to geometric models, to define mesh areas, to generate finite element mesh and to execute adaptive mesh refinement techniques. The importance of automated mesh generation and refinement is highlighted and various optimization methods are considered. Further, a special attention is given to integration issues of shape optimization capabilities into CAD environment. To demonstrate the developed algorithm, an automotive rear suspension torque arm is selected for finite element analysis and shape optimization. The practical example highlights the important features of IDEAS programs and analysis results are explained by plotting stress contours for different steps during the optimization procedure. As a whole, the stress has been given to m develop a general approach, rather than concentrating on specialized areas of shape optimal design process

Pre- and postprocessing techniques for determining goodness of computational meshes

Research in error estimation, mesh conditioning, and solution enhancement for finite element, finite difference, and finite volume methods has been incorporated into AUDITOR, a modern, user-friendly code, which operates on 2D and 3D unstructured neutral files to improve the accuracy and reliability of computational results. Residual error estimation capabilities provide local and global estimates of solution error in the energy norm. Higher order results for derived quantities may be extracted from initial solutions. Within the X-MOTIF graphical user interface, extensive visualization capabilities support critical evaluation of results in linear elasticity, steady state heat transfer, and both compressible and incompressible fluid dynamics