Evolutionary approaches to optimisation in rough machining

This thesis concerns the use of Evolutionary Computation to optimise the sequence and selection of tools and machining parameters in rough milling applications. These processes are not automated in current Computer-Aided Manufacturing (CAM) software and this work, undertaken in collaboration with an industrial partner, aims to address this. Related research has mainly approached tool sequence optimisation using only a single tool type, and machining parameter optimisation of a single-tool sequence. In a real world industrial setting, tools with different geometrical profiles are commonly used in combination on rough machining tasks in order to produce components with complex sculptured surfaces. This work introduces a new representation scheme and search operators to support the use of the three most commonly used tool types: end mill, ball nose and toroidal. Using these operators, single-objective metaheuristic algorithms are shown to find near-optimal solutions, while surveying only a small number of tool sequences. For the first time, a multi-objective approach is taken to tool sequence optimisation. The process of ‘multi objectivisation’ is shown to offer two benefits: escaping local optima on deceptive multimodal search spaces and providing a selection of tool sequence alternatives to a machinist. The multi-objective approach is also used to produce a varied set of near-Pareto optimal solutions, offering different trade-offs between total machining time and total tooling costs, simultaneously optimising tool sequences and the cutting speeds of individual tools. A challenge for using computationally expensive CAM software, important for real world machining, is the time cost of evaluations. An asynchronous parallel evolutionary optimisation system is presented that can provide a significant speed up, even in the presence of heterogeneous evaluation times produced by variable length tool sequences. This system uses a distributed network of processors that could be easily and inexpensively implemented on existing commercial hardware, and accessible to even small workshops

Parallel optimization algorithms for high performance computing : application to thermal systems

The need of optimization is present in every field of engineering. Moreover, applications requiring a multidisciplinary approach in order to make a step forward are increasing. This leads to the need of solving complex optimization problems that exceed the capacity of human brain or intuition. A standard way of proceeding is to use evolutionary algorithms, among which genetic algorithms hold a prominent place. These are characterized by their robustness and versatility, as well as their high computational cost and low convergence speed. Many optimization packages are available under free software licenses and are representative of the current state of the art in optimization technology. However, the ability of optimization algorithms to adapt to massively parallel computers reaching satisfactory efficiency levels is still an open issue. Even packages suited for multilevel parallelism encounter difficulties when dealing with objective functions involving long and variable simulation times. This variability is common in Computational Fluid Dynamics and Heat Transfer (CFD & HT), nonlinear mechanics, etc. and is nowadays a dominant concern for large scale applications. Current research in improving the performance of evolutionary algorithms is mainly focused on developing new search algorithms. Nevertheless, there is a vast knowledge of sequential well-performing algorithmic suitable for being implemented in parallel computers. The gap to be covered is efficient parallelization. Moreover, advances in the research of both new search algorithms and efficient parallelization are additive, so that the enhancement of current state of the art optimization software can be accelerated if both fronts are tackled simultaneously. The motivation of this Doctoral Thesis is to make a step forward towards the successful integration of Optimization and High Performance Computing capabilities, which has the potential to boost technological development by providing better designs, shortening product development times and minimizing the required resources. After conducting a thorough state of the art study of the mathematical optimization techniques available to date, a generic mathematical optimization tool has been developed putting a special focus on the application of the library to the field of Computational Fluid Dynamics and Heat Transfer (CFD & HT). Then the main shortcomings of the standard parallelization strategies available for genetic algorithms and similar population-based optimization methods have been analyzed. Computational load imbalance has been identified to be the key point causing the degradation of the optimization algorithm¿s scalability (i.e. parallel efficiency) in case the average makespan of the batch of individuals is greater than the average time required by the optimizer for performing inter-processor communications. It occurs because processors are often unable to finish the evaluation of their queue of individuals simultaneously and need to be synchronized before the next batch of individuals is created. Consequently, the computational load imbalance is translated into idle time in some processors. Several load balancing algorithms have been proposed and exhaustively tested, being extendable to any other population-based optimization method that needs to synchronize all processors after the evaluation of each batch of individuals. Finally, a real-world engineering application that consists on optimizing the refrigeration system of a power electronic device has been presented as an illustrative example in which the use of the proposed load balancing algorithms is able to reduce the simulation time required by the optimization tool.El aumento de las aplicaciones que requieren de una aproximación multidisciplinar para poder avanzar se constata en todos los campos de la ingeniería, lo cual conlleva la necesidad de resolver problemas de optimización complejos que exceden la capacidad del cerebro humano o de la intuición. En estos casos es habitual el uso de algoritmos evolutivos, principalmente de los algoritmos genéticos, caracterizados por su robustez y versatilidad, así como por su gran coste computacional y baja velocidad de convergencia. La multitud de paquetes de optimización disponibles con licencias de software libre representan el estado del arte actual en tecnología de optimización. Sin embargo, la capacidad de adaptación de los algoritmos de optimización a ordenadores masivamente paralelos alcanzando niveles de eficiencia satisfactorios es todavía una tarea pendiente. Incluso los paquetes adaptados al paralelismo multinivel tienen dificultades para gestionar funciones objetivo que requieren de tiempos de simulación largos y variables. Esta variabilidad es común en la Dinámica de Fluidos Computacional y la Transferencia de Calor (CFD & HT), mecánica no lineal, etc. y es una de las principales preocupaciones en aplicaciones a gran escala a día de hoy. La investigación actual que tiene por objetivo la mejora del rendimiento de los algoritmos evolutivos está enfocada principalmente al desarrollo de nuevos algoritmos de búsqueda. Sin embargo, ya se conoce una gran variedad de algoritmos secuenciales apropiados para su implementación en ordenadores paralelos. La tarea pendiente es conseguir una paralelización eficiente. Además, los avances en la investigación de nuevos algoritmos de búsqueda y la paralelización son aditivos, por lo que el proceso de mejora del software de optimización actual se verá incrementada si se atacan ambos frentes simultáneamente. La motivación de esta Tesis Doctoral es avanzar hacia una integración completa de las capacidades de Optimización y Computación de Alto Rendimiento para así impulsar el desarrollo tecnológico proporcionando mejores diseños, acortando los tiempos de desarrollo del producto y minimizando los recursos necesarios. Tras un exhaustivo estudio del estado del arte de las técnicas de optimización matemática disponibles a día de hoy, se ha diseñado una librería de optimización orientada al campo de la Dinámica de Fluidos Computacional y la Transferencia de Calor (CFD & HT). A continuación se han analizado las principales limitaciones de las estrategias de paralelización disponibles para algoritmos genéticos y otros métodos de optimización basados en poblaciones. En el caso en que el tiempo de evaluación medio de la tanda de individuos sea mayor que el tiempo medio que necesita el optimizador para llevar a cabo comunicaciones entre procesadores, se ha detectado que la causa principal de la degradación de la escalabilidad o eficiencia paralela del algoritmo de optimización es el desequilibrio de la carga computacional. El motivo es que a menudo los procesadores no terminan de evaluar su cola de individuos simultáneamente y deben sincronizarse antes de que se cree la siguiente tanda de individuos. Por consiguiente, el desequilibrio de la carga computacional se convierte en tiempo de inactividad en algunos procesadores. Se han propuesto y testado exhaustivamente varios algoritmos de equilibrado de carga aplicables a cualquier método de optimización basado en una población que necesite sincronizar los procesadores tras cada tanda de evaluaciones. Finalmente, se ha presentado como ejemplo ilustrativo un caso real de ingeniería que consiste en optimizar el sistema de refrigeración de un dispositivo de electrónica de potencia. En él queda demostrado que el uso de los algoritmos de equilibrado de carga computacional propuestos es capaz de reducir el tiempo de simulación que necesita la herramienta de optimización

Green profit design for lifecycle

“Green Profit” refers to economic profits generated by an environmentally sustainable business. As awareness of sustainability increases and environmental regulations become more stringent, manufacturers are faced with the challenge of making a green profit in their businesses. Recovering end-of-life products after customer use is a promising solution to this challenge. Various recovery options, including reuse, refurbishment, remanufacturing, and material recovery, can make it possible for companies to comply with environmental legislation and also gain social and economic benefits. This dissertation presents a design approach, referred to as “Green Profit Design,” to help maximize green profits from end-of-life recovery of products. Green Profit Design is a Design for Recovery approach that facilitates green and profitable end-of-life recovery of products by establishing a clear link between product design and end-of-life recovery. Product design features, including product architecture, functional performance, and material properties, greatly affect the economic and environmental performances of end-of-life recovery. Therefore, the most important factors in achieving green profit are an understanding of how design decisions affect actual end-of-life recovery and understanding the economic and environmental implications of the design. The Design for Recovery methods introduced in this dissertation evaluate product design from a recovery perspective and provide a quantitative assessment of how good or how bad a product design is in terms of both recovery profit and environmental impact. The methods can be utilized for either design improvement or design selection. An original contribution of this dissertation is that it provides the foundation for integrating the different perspectives on end-of-life recovery of different domains, i.e., design engineering, environmental engineering, and business. Another important contribution is its thorough coverage of recovery processes. In addition to technical and operational issues, the methods in this dissertation also cover the recovery processes at the front end (i.e., product take-back and reverse logistics) and the back end (i.e., remarketing of recovered items) and suggest an advanced approach for coordinating and managing the entire process more effectively. This dissertation presents two empirical studies, four Design for Recovery methods, and three extended studies on further refinement of the four methods. Using statistical analyses, the empirical studies investigate the challenges that the Design for Recovery approach must overcome. The current industry practice of electronics recovery is examined to gain a better understanding of the design issues associated with end-of-life recovery. The Design for Recovery methods focus on evaluating the design of the original product from a recovery perspective. The first three methods consider the case in which the second-life products recovered from the end-of-life products have a pre-defined design. Optimization models for evaluating a single product and for evaluating the design of a family of products are presented, and the effects of product obsolescence and deterioration at the time of end-of-life recovery are also analyzed. The fourth method is focused more on how to remarket end-of-life products, and it provides the advanced tools required for market positioning to optimize the design and the price of a second-life product. The three extended studies focus on environmental implications of end-of-life recovery and discuss appropriate timing utilizing recovery principles. End-of-life recovery is basically a strategy for extending the life of a product by reusing, refurbishing, or remanufacturing that product. The studies demonstrate that an extended lifetime may not always be environmentally sustainable, and that shortening the lifetime may actually be better in some cases. To help decide on the optimal lifetime strategy for a given product, lifecycle assessment (LCA) approaches for a large-scale system are discussed, and an analytical model is proposed for planning optimal lifetime of a given product based on the LCA approach