Multiscale Design for Solid Freeform Fabrication

One of the advantages of solid freeform fabrication is the ability to fabricate complex structures on multiple scales, from the macroscale features of an overall part to the mesoscale topology of its internal architecture and even the microstructure or composition of the constituent material. This manufacturing freedom poses the challenge of designing across these scales, especially when a part with designed mesostructure is part of a larger system with changing requirements that propagate across scales. A setbased multiscale design method is presented for coordinating design across scales and reducing iterative redesign of SFF parts and their mesostructures. The method is applied to design a miniature unmanned aerial vehicle system. The system is decomposed into disciplinary subsystems and constituent parts, including wings with honeycomb mesostructures that are topologically tailored for stiffness and strength and fabricated with selective laser sintering. The application illustrates how the design of freeform parts can be coordinated more efficiently with the design of parent systems.Mechanical Engineerin

The Application of Memetic Algorithms for Forearm Crutch Design: A Case Study

Product design has normally been performed by teams, each with expertise in a specific discipline such as material, structural, and electrical systems. Traditionally, each team would use its member\u27s experience and knowledge to develop the design sequentially. Collaborative design decisions explore the use of optimization methods to solve the design problem incorporating a number of disciplines simultaneously. It is known that such optimized product design is superior to the design found by optimizing each discipline sequentially due to the fact that it enables the exploitation of the interactions between the disciplines. In this paper, a bi-level decentralized framework based on Memetic Algorithm (MA) is proposed for collaborative design decision making using forearm crutch as the case. Two major decisions are considered: the weight and the strength. We introduce two design agents for each of the decisions. At the system level, one additional agent termed facilitator agent is created. Its main function is to locate the optimal solution for the system objective function which is derived from the Pareto concept. Thus to Pareto optimum for both weight and strength is obtained. It is demonstrated that the proposed model can converge to Pareto solutions

State-of-the-art in aerodynamic shape optimisation methods

Aerodynamic optimisation has become an indispensable component for any aerodynamic design over the past 60 years, with applications to aircraft, cars, trains, bridges, wind turbines, internal pipe flows, and cavities, among others, and is thus relevant in many facets of technology. With advancements in computational power, automated design optimisation procedures have become more competent, however, there is an ambiguity and bias throughout the literature with regards to relative performance of optimisation architectures and employed algorithms. This paper provides a well-balanced critical review of the dominant optimisation approaches that have been integrated with aerodynamic theory for the purpose of shape optimisation. A total of 229 papers, published in more than 120 journals and conference proceedings, have been classified into 6 different optimisation algorithm approaches. The material cited includes some of the most well-established authors and publications in the field of aerodynamic optimisation. This paper aims to eliminate bias toward certain algorithms by analysing the limitations, drawbacks, and the benefits of the most utilised optimisation approaches. This review provides comprehensive but straightforward insight for non-specialists and reference detailing the current state for specialist practitioners

An application of parallel computation to Collaborative Optimization

Multidisciplinary Design Optimization (MDO) has evolved as a discipline which provides a body of methods and techniques to assist engineers in solving large scale design problems. There are many frameworks for formulating MDO problems. These frameworks can be broadly classified as single-level or bi-level formulations. Collaborative Optimization (CO) is one of the popular bi-level formulations to solve an MDO problem. There are numerous design optimization problems which are highly CPU time intensive and require a long simulation time. With the advent of cheaper and faster available PC’s, distributed parallel computer clusters have become very popular. These clusters provide large computing power and can be used to solve problems faster and more efficiently. This research is an attempt to take advantage of the computational power of parallel computers in the field of design Optimization. The robust design optimization of an Internal Combustion Engine has been formulated using CO and implemented using parallel computers. Considerable savings in Wall Time has been achieved. A generic strategy for solving similar problems has also been devised. A benchmarking program has also been developed to assess theoretical speedup for any problem size. This program uses the Collaborative Optimization framework and simulates a design optimization on distributed memory clusters

APPROXIMATION ASSISTED MULTIOBJECTIVE AND COLLABORATIVE ROBUST OPTIMIZATION UNDER INTERVAL UNCERTAINTY

Optimization of engineering systems under uncertainty often involves problems that have multiple objectives, constraints and subsystems. The main goal in these problems is to obtain solutions that are optimum and relatively insensitive to uncertainty. Such solutions are called robust optimum solutions. Two classes of such problems are considered in this dissertation. The first class involves Multi-Objective Robust Optimization (MORO) problems under interval uncertainty. In this class, an entire system optimization problem, which has multiple nonlinear objectives and constraints, is solved by a multiobjective optimizer at one level while robustness of trial alternatives generated by the optimizer is evaluated at the other level. This bi-level (or nested) MORO approach can become computationally prohibitive as the size of the problem grows. To address this difficulty, a new and improved MORO approach under interval uncertainty is developed. Unlike the previously reported bi-level MORO methods, the improved MORO performs robustness evaluation only for optimum solutions and uses this information to iteratively shrink the feasible domain and find the location of robust optimum solutions. Compared to the previous bi-level approach, the improved MORO significantly reduces the number of function calls needed to arrive at the solutions. To further improve the computational cost, the improved MORO is combined with an online approximation approach. This new approach is called Approximation-Assisted MORO or AA-MORO. The second class involves Multiobjective collaborative Robust Optimization (McRO) problems. In this class, an entire system optimization problem is decomposed hierarchically along user-defined domain specific boundaries into system optimization problem and several subsystem optimization subproblems. The dissertation presents a new Approximation-Assisted McRO (AA-McRO) approach under interval uncertainty. AA-McRO uses a single-objective optimization problem to coordinate all system and subsystem optimization problems in a Collaborative Optimization (CO) framework. The approach converts the consistency constraints of CO into penalty terms which are integrated into the subsystem objective functions. In this way, AA-McRO is able to explore the design space and obtain optimum design solutions more efficiently compared to a previously reported McRO. Both AA-MORO and AA-McRO approaches are demonstrated with a variety of numerical and engineering optimization examples. It is found that the solutions from both approaches compare well with the previously reported approaches but require a significantly less computational cost. Finally, the AA-MORO has been used in the development of a decision support system for a refinery case study in order to facilitate the integration of engineering and business decisions using an agent-based approach

Multidisciplinary Design Optimization for Space Applications

Multidisciplinary Design Optimization (MDO) has been increasingly studied in aerospace engineering with the main purpose of reducing monetary and schedule costs. The traditional design approach of optimizing each discipline separately and manually iterating to achieve good solutions is substituted by exploiting the interactions between the disciplines and concurrently optimizing every subsystem. The target of the research was the development of a flexible software suite capable of concurrently optimizing the design of a rocket propellant launch vehicle for multiple objectives. The possibility of combining the advantages of global and local searches have been exploited in both the MDO architecture and in the selected and self developed optimization methodologies. Those have been compared according to computational efficiency and performance criteria. Results have been critically analyzed to identify the most suitable optimization approach for the targeted MDO problem