Nonintrusive parametric NVH study of a vehicle body structure

This is an Accepted Manuscript of an article published by Taylor & Francis Group in Mechanics based design of structures and machines on 27/06/22, available online at: http://www.tandfonline.com/10.1080/15397734.2022.2098140A reduced order model technique is presented to perform the parametric Noise, Vibration and Harshness (NVH) study of a vehicle body-in-white (BIW) structure characterized by material and shape design variables. The ultimate goal is to develop a methodology which allows to efficiently explore the variation in the design space of the BIW static and dynamic global stiffnesses, such that the NVH performance can be evaluated already in the preliminary phase of the development process. The proposed technique is based on the proper generalized decomposition (PGD) method. The obtained PGD solution presents an explicit dependency on the introduced design variables, which allows to obtain solutions in 0.1 milliseconds and therefore opens the door to fast optimization studies and real-time visualizations of the results in a pre-defined range of parameters. The method is nonintrusive, such that an interaction with commercial software is possible. A parametrized finite element (FE) model of the BIW is built by means of the ANSA CAE preprocessor software, which allows to account for material and geometric parameters. A comparison between the parametric NVH solutions and the full-order FE simulations is performed using the MSC-Nastran software, to validate the accuracy of the proposed method. In addition, an optimization study is presented to find the optimal materials and shape properties with respect to the NVH performance. Finally, in order to support the designers in the decision-making process, a graphical interface app is developed which allows to visualize in real-time how changes in the design variables affect pre-defined quantities of interest.This project is part of the Marie Skłodowska-Curie ITN-EJD ProTechTion funded by the European Union Horizon 2020 research and innovation program with Grant Number 764636. The work of Fabiola Cavaliere, Sergio Zlotnik and Pedro D ıez is partially supported by the MCIN/AEI/10.13039/501100011033, Spain (Grant Number: PID2020-113463RB-C32, PID2020-113463RB-C33 and CEX2018-000797-S). Ruben Sevilla also acknowledges the support of the Engineering and Physical Sciences Research Council (Grant Number: EP/T009071/1).Peer ReviewedPostprint (published version

Multi-Objective structural optimization of repairs of blisk blades

Modern manufacturing technologies offer multiple options to extend the service life of expensive jet engine components through repairs. In this context, the repair processes of blade-integrated disks (blisks) are of particular interest, as the complex design makes replacement of this part very costly. However, currently, repairs of blisks are mainly done manually and repair design decisions still rely on the expertise of maintenance technicians. From a scientific perspective, these subjective, experience-based decisions are a major drawback, as today’s computational methods allow for systematic analysis and evaluation of design alternatives. The present doctoral thesis contributes to the decision-making process related to the repair of blisk blades by blending and patching by providing an engineering optimization framework and simulation routines for structural assessment of different repair designs. First, an object-oriented optimization framework is developed that is ideally suited to address engineering optimization problems such as blisk repair optimization. The design of the software architecture is chosen to achieve a high degree of flexibility and modularity. In particular, the framework provides a unified interface for global and local derivative-free optimization algorithms and custom engineering optimization problems. Thereby, optimization of single- as well as multi-objective problems is supported. The broad applicability of the framework in engineering optimization is demonstrated using examples from wind energy research. Furthermore, the optimization framework forms a suitable environment for structural multi-objective optimization of blend and patch repairs. The second part of this thesis is devoted to the application of the optimization framework to blend repairs of a compressor blisk. The geometry of the removed blade part and the resulting blend is parameterized by three geometric design variables. The two objectives of the optimization correspond to two modal criteria, because especially the vibration behavior of blades is affected by this kind of geometric modification. To check if frequency requirements are harmed by the repair the first objective reflects the deviation of the natural frequencies of the repaired blade to the natural frequencies of the nominal blade. The second objective considers resonance conditions by evaluating the proximity of natural frequencies to excitation frequencies. Pareto optimal repair designs are found by solving the derived optimization problem using appropriate structural mechanics models of a blade sector and employing the developed optimization framework. By analyzing the optimal blend shapes for two different damage patterns, it is shown that the characteristics of Pareto frontiers, like the occurrence of discontinuities, are damage-specific. Therefore, it is concluded that design decisions on blend repairs have to be made on a case-by-case basis. The third part of this thesis is concerned with the multi-objective optimization of patch repairs. While blend repairs change the blade geometry, patch repairs restore the original blade contour. In terms of structural integrity, the most significant modification due to patching is hence associated with the welding process to join patch and blade. The remaining residual stresses, affect the strength of the repaired blade, are therefore the most critical aspect of patch repairs. Utilizing the engineering optimization framework and the parametric simulation model, a multi-objective optimization problem is solved considering the length of the weld and the fatigue strength of the repaired blade. In addition to fatigue strength properties, the weld length is selected as an optimization goal, since the manufacturing effort of the high-tech repair is of practical importance. Pareto optimal repair designs are presented for a damage pattern at the leading edge. The optimization results are further complemented by subsequent thermal and mechanical simulations of the welding and heat treatment process. Different patch geometries are classified from the Pareto optimal solutions. Depending on the preferences in terms of weld length and the High-Cycle Fatigue strength of different load cases, short or long patches are to be used. In addition, the results show that some potential patch designs are not optimal in any case, and therefore can be completely excluded. Finally, the benefits of the unified interface of the engineering optimization framework are emphasized. Different optimization settings of a patch repair optimization are presented and compared utilizing the hypervolume metric. Concluding remarks on the potential of computational methods for improved repair design and an outlook on future maintenance of blisks complete this work.DFG/SFB 871/119 193 472./E

Static and dynamic global stiffness analysis for automotive pre-design

Tesi en modalitat de cotutela: Universitat Politècnica de Catalunya i Swansea UniversityIn order to be worldwide competitive, the automotive industry is constantly challenged to produce higher quality vehicles in the shortest time possible and with the minimum costs of production. Most of the problems with new products derive from poor quality design processes, which often leads to undesired issues in a stage where changes are extremely expensive. During the preliminary design phase, designers have to deal with complex parametric problems where material and geometric characteristics of the car components are unknown. Any change in these parameters might significantly affect the global behaviour of the car. A target which is very sensitive to small variations of the parameters is the noise and vibration response of the vehicle (NVH study), which strictly depends on its global static and dynamic stiffness. In order to find the optimal solution, a lot of configurations exploring all the possible parametric combinations need to be tested. The current state of the art in the automotive design context is still based on standard numerical simulations, which are computationally very expensive when applied to this kind of multidimensional problems. As a consequence, a limited number of configurations is usually analysed, leading to suboptimal products. An alternative is represented by reduced order method (ROM) techniques, which are based on the idea that the essential behaviour of complex systems can be accurately described by simplified low-order models. This thesis proposes a novel extension of the proper generalized decomposition (PGD) method to optimize the design process of a car structure with respect to its global static and dynamic stiffness properties. In particular, the PGD method is coupled with the inertia relief (IR) technique and the inverse power method (IPM) to solve, respectively, the parametric static and dynamic stiffness analysis of an unconstrained car structure and extract its noise and vibrations properties. A main advantage is that, unlike many other ROM methods, the proposed approach does not require any pre-processing phase to collect prior knowledge of the solution. Moreover, the PGD solution is computed with only one offline computation and presents an explicit dependency on the introduced design variables. This allows to compute the solutions at a negligible computational cost and therefore opens the door to fast optimisation studies and real-time visualisations of the results in a pre-defined range of parameters. A novel algebraic approach is also proposed which allows to involve both material and complex geometric parameters, such that shape optimisation studies can be performed. In addition, the method is developed in a nonintrusive format, such that an interaction with commercial software is possible, which makes it particularly interesting for industrial applications. Finally, in order to support the designers in the decision-making process, a graphical interface app is developed which allows to visualise in real-time how changes in the design variables affect pre-defined quantities of interest.Para ser competitiva en todo el mundo, la industria del automóvil se enfrenta constantemente al reto de producir vehículos de mayor calidad en el menor tiempo posible y con los mínimos costes de producción. La mayor parte de los problemas de los nuevos productos derivan de la mala calidad de los procesos de diseño, que a menudo conduce a problemas no deseados en una fase en la que los cambios son extremadamente caros. Durante la fase de diseño preliminar, los diseñadores tienen que enfrentarse a complejos problemas paramétricos en los que se desconocen las características materiales y geométricas de los componentes del coche. Cualquier cambio en estos parámetros puede afectar significativamente al comportamiento global del coche. Un objetivo muy sensible a pequeñas variaciones de los parámetros es la respuesta al ruido y las vibraciones del vehículo (estudio NVH), que depende estrictamente de su rigidez global estática y dinámica. Para encontrar la solución óptima, es necesario probar muchas configuraciones que exploren todas las combinaciones paramétricas posibles. El estado actual de la técnica en el contexto del diseño de automóviles sigue basándose en simulaciones numéricas estándar, que son muy costosas desde el punto de vista de cálculo cuando se aplican a este tipo de problemas multidimensionales. Como consecuencia, se suele analizar un número limitado de configuraciones, lo que conduce a productos subóptimos. Una alternativa la representan las técnicas de reduced order modelling (ROM), que se basan en la idea de que el comportamiento esencial de los sistemas complejos puede describirse con precisión mediante modelos simplificados. Esta tesis propone una nueva extensión del método de proper generalised decomposition (PGD) para optimizar el proceso de diseño de la estructura de un automóvil con respecto a sus propiedades globales de rigidez estática y dinámica. En particular, el método PGD se acopla con la técnica de inertia relief (IR) y el inverse power method (IPM) para resolver, respectivamente, el análisis paramétrico de la rigidez estática y dinámica de una estructura de coche sin restricciones y extraer sus propiedades de ruido y vibraciones. Una de las principales ventajas es que, a diferencia de muchos otros métodos ROM, el enfoque propuesto no requiere ninguna fase de preprocesamiento para recoger el conocimiento previo de la solución. Además, la solución del PGD se calcula con un solo cálculo fuera de línea y presenta una dependencia explícita de las variables de diseño introducidas. Esto permite calcular las soluciones con un coste computacional insignificante y, por tanto, abre la puerta a estudios de optimización rápidos y a la visualización en tiempo real de los resultados en un rango predefinido de parámetros. También se propone un nuevo enfoque algebraico que permite involucrar tanto el material como los parámetros geométricos complejos, de manera que se pueden realizar estudios de optimización de la forma. Además, el método se desarrolla en un formato no intrusivo, de forma que es posible la interacción con software comercial, lo que lo hace especialmente interesante para aplicaciones industriales. Por último, para apoyar a los diseñadores en el proceso de toma de decisiones, se desarrolla una aplicación de interfaz gráfica que permite visualizar en tiempo real cómo los cambios en las variables de diseño afectan a las cantidades de interés predefinidas.Postprint (published version

Static and dynamic global stiffness analysis for automotive pre-design

In order to be worldwide competitive, the automotive industry is constantly challenged to produce higher quality vehicles in the shortest time possible and with the minimum costs of production. Most of the problems with new products derive from poor quality design processes, which often leads to undesired issues in a stage where changes are extremely expensive. During the preliminary design phase, designers have to deal with complex parametric problems where material and geometric characteristics of the car components are unknown. Any change in these parameters might significantly affect the global behaviour of the car. A target which is very sensitive to small variations of the parameters is the noise and vibration response of the vehicle (NVH study), which strictly depends on its global static and dynamic stiffness. In order to find the optimal solution, a lot of configurations exploring all the possible parametric combinations need to be tested. The current state of the art in the automotive design context is still based on standard numerical simulations, which are computationally very expensive when applied to this kind of multidimensional problems. As a consequence, a limited number of configurations is usually analysed, leading to suboptimal products. An alternative is represented by reduced order method (ROM) techniques, which are based on the idea that the essential behaviour of complex systems can be accurately described by simplified low-order models.This thesis proposes a novel extension of the proper generalized decomposi-tion (PGD) method to optimize the design process of a car structure with respect to its global static and dynamic stiffness properties. In particular, the PGD method is coupled with the inertia relief (IR) technique and the inverse power method (IPM) to solve, respectively, the parametric static and dynamic stiffness analysis of an unconstrained car structure and extract its noise and vibrations properties. A main advantage is that, unlike many other ROM methods, the proposed approach does not require any pre-processing phase to collect prior knowledge of the solution. Moreover, the PGD solution is computed with only one offline computation and presents an explicit dependency on the introduced design variables. This allows to compute the solutions at a negligible computational cost and therefore opens the door to fast optimisation studies and real-time visualisations of the results in a pre-defined range of parameters. A novel algebraic approach is also proposed which allows to involve both material and com-plex geometric parameters, such that shape optimisation studies can be performed. In addition, the method is developed in a nonintrusive format, such that an interaction with commercial software is possible, which makes it particularly interesting for industrial applications. Finally, in order to support the designers in the decision-making process, a graphical interface app is developed which allows to visualise in real-time how changes in the design variables affect pre-defined quantities of interest

Kinta District Driving Cycle Analysis by Using DC-TRAD Conceptual Model

An accurate technique of driving cycle development is important. Such a technique should be dominantly based on real-world driving behavior to ensure it represents the profile of the selected route. A driving cycle often is the combination of analyses of huge numbers of micro-trips under different conditions of traffic. This research is an initiative to improve the accuracy of the method of data collection; this contributes directly to one of the major procedures of driving cycle development, namely data collection. A driving cycle tracking device (DC-TRAD) is a device developed to improve the data collection strategy with integration of Internet-of-Things to manage the huge amount of data collected. A conceptual design of DC-TRAD is developed, and the flexibility of the device is made use in this research to compare and analyze the driving cycle of Kinta district.The authors would like to thank the Ministry of Education Malaysia for providing financial assistance under MG3+1 2022 (MG3+1/ 2022/ 53495/ UMT) grant and the Faculty of Ocean Engineering Technology and Informatics, UMT for all their technical and research support for this work to be successfully completed

Mobile 5G millimeter-wave multi-antenna systems

In reference to IEEE copyrighted material which is used with permission in this thesis, the IEEE does not endorse any of Universitat Politècnica de Catalunya's products or services. Internal or personal use of this material is permitted. If interested in reprinting/republishing IEEE copyrighted material for advertising or promotional purposes or for creating new collective works for resale or redistribution, please go to http://www.ieee.org/publications_standards/publications/rights/rights_link.html to learn how to obtain a License from RightsLink.Tesi en modalitat de compendi de publicacionsMassive antenna architectures and millimeter-wave bands appear on the horizon as the enabling technologies of future broadband wireless links, promising unprecedented spectral efficiency and data rates. In the recently launched fifth generation of mobile communications, millimetric bands are already introduced but their widespread deployment still presents several feasibility issues. In particular, high-mobility environments represent the most challenging scenario when dealing with directive patterns, which are essential for the adequate reception of signals at those bands. Vehicular communications are expected to exploit the full potential of future generations due to the massive number of connected users and stringent requirements in terms of reliability, latency, and throughput while moving at high speeds. This thesis proposes two solutions to completely take advantage of multi-antenna systems in those cases: beamwidth adaptation of cellular stations when tracking vehicular users based on positioning and Doppler information and a tailored radiation diagram from a panel-based system of antennas mounted on the vehicle. Apart from cellular base stations and vehicles, a third entity that cannot be forgotten in future mobile communications are pedestrians. Past generations were developed around the figure of human users and, now, they must still be able to seamlessly connect with any other user of the network and exploit the new capabilities promised by 5G. The use of millimeter-waves is already been considered by handset manufacturers but the impact of the user (and the interaction with the phone) is drastically changed. The last part of this thesis is devoted to the study of human user dynamics and how they influence the achievable coverage with different distributed antenna systems on the phone.Les arquitectures massives d'antenes i les bandes mil·limètriques apareixen a l'horitzó com les tecnologies que impulsaran els futurs enllaços sense fils amb gran ample de banda i prometen una eficiència espectral i velocitat de transmissió sense precedents. A la recent cinquena generació de comunicacions mòbils, les bandes mil·limètriques ja en són una part constitutiva però el seu desplegament encara presenta certes dificultats. En concret, els entorns d'alta mobilitat representen el major repte quan es fan servir diagrames de radiació directius, els quals són essencials per una correcta recepció del senyal en aquestes bandes. S'espera que les comunicacions vehiculars delimitin les capacitats de les xarxes en futures generacions degut al gran nombre d'usuaris simultanis i els requeriments estrictes en termes de fiabilitat, retard i flux de dades mentre es mouen a grans velocitats. Aquesta tesi proposa dues solucions per tal d'explotar al màxim els sistemes de múltiples antenes en tals casos: un ample de feix adaptatiu de les estacions bases quan estiguin fent el seguiment d'un vehicle usuari basat en informació de la posició i el Doppler i el disseny d'un diagrama de radiació adequat al costat del vehicle basat en una estructura de múltiples panells muntats a l'estructura del mateix. A més de les estacions base i els vehicles, un tercer element que no pot ser obviat en aquests escenaris són els vianants. Les generacions anteriors van ser desenvolupades al voltant de la figura d'usuaris humans i ara han de seguir tenint la capacitat de connexió ininterrumpuda amb la resta d'usuaris i explotar les capacitats de 5G. L'ús de frequències mil·limètriques també es té en compte en la fabricació de telèfons mòbils però l'impacte de l'usuari és completament diferent. La última part de la tesis tracta l'estudi de les dinàmiques de l'usuari humà i com influeixen en la cobertura amb diferent sistemes distribuïts d'antenes.Postprint (published version

An integrated framework for developing generic modular reconfigurable platforms for micro manufacturing and its implementation

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.The continuing trends of miniaturisation, mass customisation, globalisation and wide use of the Internet have great impacts upon manufacturing in the 21st century. Micro manufacturing will play an increasingly important role in bridging the gap between the traditional precision manufacturing and the emerging technologies like MEMS/NEMS. The key requirements for micro manufacturing in this context are hybrid manufacturing capability, modularity, reconfigurability, adaptability and energy/resource efficiency. The existing design approaches tend to have narrow scope and are largely limited to individual manufacturing processes and applications. The above requirements demand a fundamentally new approach to the future applications of micro manufacturing so as to obtain producibility, predictability and productivity covering the full process chains and value chains. A novel generic modular reconfigurable platform (GMRP) is proposed in such a context. The proposed GMRP is able to offer hybrid manufacturing capabilities, modularity, reconfigurablity and adaptivity as both an individual machine tool and a micro manufacturing system, and provides a cost effective solution to high value micro manufacturing in an agile, responsive and mass customisation manner. An integrated framework has been developed to assist the design of GMRPs due to their complexity. The framework incorporates theoretical GMRP model, design support system and extension interfaces. The GMRP model covers various relevant micro manufacturing processes and machine tool elements. The design support system includes a user-friendly interface, a design engine for design process and design evaluation, together with scalable design knowledge base and database. The functionalities of the framework can also be extended through the design support system interface, the GMRP interface and the application interface, i.e. linking to external hardware and/or software modules. The design support system provides a number of tools for the analysis and evaluation of the design solutions. The kinematic simulation of machine tools can be performed using the Virtual Reality toolbox in Matlab. A module has also been developed for the multiscale modelling, simulation and results analysis in Matlab. A number of different cutting parameters can be studied and the machining performance can be subsequently evaluated using this module. The mathematical models for a non-traditional micro manufacturing process, micro EDM, have been developed with the simulation performed using FEA. Various design theories and methodologies have been studied, and the axiomatic design theory has been selected because of its great power and simplicity. It has been applied in the conceptual design of GMRP and its design support system. The implementation of the design support system is carried out using Matlab, Java and XML technologies. The proposed GMRP and framework have been evaluated through case studies and experimental results