AI-based design methodologies for hot form quench (HFQ®)

This thesis aims to develop advanced design methodologies that fully exploit the capabilities of the Hot Form Quench (HFQ®) stamping process in stamping complex geometric features in high-strength aluminium alloy structural components. While previous research has focused on material models for FE simulations, these simulations are not suitable for early-phase design due to their high computational cost and expertise requirements. This project has two main objectives: first, to develop design guidelines for the early-stage design phase; and second, to create a machine learning-based platform that can optimise 3D geometries under hot stamping constraints, for both early and late-stage design. With these methodologies, the aim is to facilitate the incorporation of HFQ capabilities into component geometry design, enabling the full realisation of its benefits. To achieve the objectives of this project, two main efforts were undertaken. Firstly, the analysis of aluminium alloys for stamping deep corners was simplified by identifying the effects of corner geometry and material characteristics on post-form thinning distribution. New equation sets were proposed to model trends and design maps were created to guide component design at early stages. Secondly, a platform was developed to optimise 3D geometries for stamping, using deep learning technologies to incorporate manufacturing capabilities. This platform combined two neural networks: a geometry generator based on Signed Distance Functions (SDFs), and an image-based manufacturability surrogate model. The platform used gradient-based techniques to update the inputs to the geometry generator based on the surrogate model's manufacturability information. The effectiveness of the platform was demonstrated on two geometry classes, Corners and Bulkheads, with five case studies conducted to optimise under post-stamped thinning constraints. Results showed that the platform allowed for free morphing of complex geometries, leading to significant improvements in component quality. The research outcomes represent a significant contribution to the field of technologically advanced manufacturing methods and offer promising avenues for future research. The developed methodologies provide practical solutions for designers to identify optimal component geometries, ensuring manufacturing feasibility and reducing design development time and costs. The potential applications of these methodologies extend to real-world industrial settings and can significantly contribute to the continued advancement of the manufacturing sector.Open Acces

Rapid feasibility assessment of components to be formed through hot stamping: A deep learning approach

The novel non-isothermal Hot Forming and cold die Quenching (HFQ) process can enable the cost-effective production of complex shaped, high strength aluminium alloy panel components. However, the unfamiliarity of designing for the new process prevents its widescale adoption in industrial settings. Recent research efforts focus on the development of advanced material models for finite element simulations, used to assess the feasibility of new component designs for the HFQ process. However, FE simulations take place late in design processes, require forming process expertise and are unsuitable for early-stage design explorations. To address these limitations, this study presents a novel application of a Convolutional Neural Network (CNN) based surrogate as a means of rapid manufacturing feasibility assessment for components to be formed using the HFQ process. A diverse dataset containing variations in component geometry, blank shapes, and processing parameters, together with corresponding physical fields is generated and used to train the model. The results show that near indistinguishable full field predictions are obtained in real time from the model when compared with HFQ simulations. This technique provides an invaluable tool to aid component design and decision making at the onset of a design process for complex-shaped components formed under HFQ conditions

NerVE: Neural Volumetric Edges for Parametric Curve Extraction from Point Cloud

Extracting parametric edge curves from point clouds is a fundamental problem in 3D vision and geometry processing. Existing approaches mainly rely on keypoint detection, a challenging procedure that tends to generate noisy output, making the subsequent edge extraction error-prone. To address this issue, we propose to directly detect structured edges to circumvent the limitations of the previous point-wise methods. We achieve this goal by presenting NerVE, a novel neural volumetric edge representation that can be easily learned through a volumetric learning framework. NerVE can be seamlessly converted to a versatile piece-wise linear (PWL) curve representation, enabling a unified strategy for learning all types of free-form curves. Furthermore, as NerVE encodes rich structural information, we show that edge extraction based on NerVE can be reduced to a simple graph search problem. After converting NerVE to the PWL representation, parametric curves can be obtained via off-the-shelf spline fitting algorithms. We evaluate our method on the challenging ABC dataset. We show that a simple network based on NerVE can already outperform the previous state-of-the-art methods by a great margin. Project page: https://dongdu3.github.io/projects/2023/NerVE/.Comment: Accepted by CVPR2023. Project page: https://dongdu3.github.io/projects/2023/NerVE

Automated Extraction of Road Information from Mobile Laser Scanning Data

Effective planning and management of transportation infrastructure requires adequate geospatial data. Existing geospatial data acquisition techniques based on conventional route surveys are very time consuming, labor intensive, and costly. Mobile laser scanning (MLS) technology enables a rapid collection of enormous volumes of highly dense, irregularly distributed, accurate geo-referenced point cloud data in the format of three-dimensional (3D) point clouds. Today, more and more commercial MLS systems are available for transportation applications. However, many transportation engineers have neither interest in the 3D point cloud data nor know how to transform such data into their computer-aided model (CAD) formatted geometric road information. Therefore, automated methods and software tools for rapid and accurate extraction of 2D/3D road information from the MLS data are urgently needed. This doctoral dissertation deals with the development and implementation aspects of a novel strategy for the automated extraction of road information from the MLS data. The main features of this strategy include: (1) the extraction of road surfaces from large volumes of MLS point clouds, (2) the generation of 2D geo-referenced feature (GRF) images from the road-surface data, (3) the exploration of point density and intensity of MLS data for road-marking extraction, and (4) the extension of tensor voting (TV) for curvilinear pavement crack extraction. In accordance with this strategy, a RoadModeler prototype with three computerized algorithms was developed. They are: (1) road-surface extraction, (2) road-marking extraction, and (3) pavement-crack extraction. Four main contributions of this development can be summarized as follows. Firstly, a curb-based approach to road surface extraction with assistance of the vehicle’s trajectory is proposed and implemented. The vehicle’s trajectory and the function of curbs that separate road surfaces from sidewalks are used to efficiently separate road-surface points from large volume of MLS data. The accuracy of extracted road surfaces is validated with manually selected reference points. Secondly, the extracted road enables accurate detection of road markings and cracks for transportation-related applications in road traffic safety. To further improve computational efficiency, the extracted 3D road data are converted into 2D image data, termed as a GRF image. The GRF image of the extracted road enables an automated road-marking extraction algorithm and an automated crack detection algorithm, respectively. Thirdly, the automated road-marking extraction algorithm applies a point-density-dependent, multi-thresholding segmentation to the GRF image to overcome unevenly distributed intensity caused by the scanning range, the incidence angle, and the surface characteristics of an illuminated object. The morphological operation is then implemented to deal with the presence of noise and incompleteness of the extracted road markings. Fourthly, the automated crack extraction algorithm applies an iterative tensor voting (ITV) algorithm to the GRF image for crack enhancement. The tensor voting, a perceptual organization method that is capable of extracting curvilinear structures from the noisy and corrupted background, is explored and extended into the field of crack detection. The successful development of three algorithms suggests that the RoadModeler strategy offers a solution to the automated extraction of road information from the MLS data. Recommendations are given for future research and development to be conducted to ensure that this progress goes beyond the prototype stage and towards everyday use