Crashworthiness design of a steel–aluminum hybrid rail using multi-response objective-oriented sequential optimization

© 2017 Elsevier Ltd Hybrid structures with different materials have aroused increasing interest for their lightweight potential and excellent performances. This study explored the optimization design of steel–aluminum hybrid structures for the highly nonlinear impact scenario. A metamodel based multi-response objective-oriented sequential optimization was adopted, where Kriging models were updated with sequential training points. It was indicated that the sequential sampling strategy was able to obtain a much higher local accuracy in the neighborhood of the optimum and thus to yield a better optimum, although it did lead to a worse global accuracy over the entire design space. Furthermore, it was observed that the steel–aluminum hybrid structure was capable of decreasing the peak force and simultaneously enhancing the energy absorption, compared to the conventional mono-material structure

Performance evaluation of metamodelling methods for engineering problems: towards a practitioner guide

YesMetamodelling or surrogate modelling techniques are frequently used across the engineering disciplines in conjunction with expensive simulation models or physical experiments. With the proliferation of metamodeling techniques developed to provide enhanced performance for specific problems, and the wide availability of a diverse choice of tools in engineering software packages, the engineering task of selecting a robust metamodeling technique for practical problems is still a challenge. This research introduces a framework for describing the typology of engineering problems, in terms of dimensionality and complexity, and the modelling conditions, reflecting the noisiness of the signals and the affordability of sample sizes, and on this basis presents a systematic evaluation of the performance of frequently used metamodeling techniques. A set of metamodeling techniques, selected based on their reported use for engineering problems (i.e. Polynomial, Radial Basis Function, and Kriging), were systematically evaluated in terms of accuracy and robustness against a carefully assembled set of 18 test functions covering different types of problems, sampling conditions and noise conditions. A set of four real-world engineering case studies covering both computer simulation and physical experiments were also analysed as validation tests for the proposed guidelines. The main conclusions drawn from the study are that Kriging model with Matérn 5/2 correlation function performs consistently well across different problem types with smooth (i.e. not noisy) data, while Kriging model with Matérn 3/2 correlation function provides robust performance under noisy conditions, except for the very high noise conditions, where the Kriging model with nugget appears to provide better models. These results provide engineering practitioners with a guide for the choice of a metamodeling technique for problem types and modelling conditions represented in the study, whereas the evaluation framework and benchmarking problems set will be useful for researchers conducting similar studies

Non-Linear Metamodeling Extensions to the Robust Parameter Design of Computer Simulations

Robust parameter design (RPD) is used to identify a systems control settings that offer a compromise between obtaining desired mean responses and minimizing the variability about those responses. Two popular combined-array strategies the response surface model (RSM) approach and the emulator approach are limited when applied to simulations. In the former case, the mean and variance models can be inadequate due to a high level of non-linearity within many simulations. In the latter case, precise mean and variance approximations are developed at the expense of extensive Monte Carlo sampling. This research combines the RSM approach\u27s efficiency with the emulator approach\u27s accuracy. Non-linear metamodeling extensions, namely through Kriging and radial basis function neural networks, are made to the RSM approach. The mean and variance of second-order Taylor series approximations of these metamodels are generated via the Multivariate Delta Method and subsequent optimization problems employing these approximations are solved. Results show that improved prediction models can be attained through the proposed approach at a reduced computational cost. Additionally, a multi-response RPD problem solving technique based on desirability functions is presented to produce a solution that is mutually robust across all responses. Lastly, quality measures are developed to provide a holistic assessment of several competing RPD strategies

Computational Intelligence and Its Applications in Uncertainty-Based Design Optimization

The large computational cost, the curse of dimensionality and the multidisciplinary nature are known as the main challenges in dealing with real-world engineering optimization problems. The consideration of inevitable uncertainties in such problems will exacerbate mentioned difficulties as much as possible. Therefore, the computational intelligence methods (also known as surrogate-models or metamodels, which are computationally cheaper approximations of the true expensive function) have been considered as powerful paradigms to overcome or at least to alleviate the mentioned issues over the last three decades. This chapter presents an extensive survey on surrogate-assisted optimization (SAO) methods. The main focus areas are the working styles of surrogate-models and the management of the metamodels during the optimization process. In addition, challenges and future trends of this field of study are introduced. Then, a comparison study will be carried out by employing a novel evolution control strategies (ECS) and recently developed efficient global optimization (EGO) method in the framework of uncertainty-based design optimization (UDO). To conclude, some open research questions in this area are discussed

Otimização eficiente global dirigida por metamodelos combinados : novos caminhos abertos pela aproximação por mínimos quadrados

Orientador: Alberto Luiz SerpaTese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia MecânicaResumo: O presente trabalho representa a compilação dos resultados anteriores dessa pesquisa no campo de metamodelos combinados e otimização eficiente global (EGO), os quais foram sumetidos para publicação em periódicos especializados. Recentemente foi implementado nesse trabalho de doutorado o algoritmo LSEGO que é uma abordagem para conduzir algoritmos tipo EGO, baseando-se em metamodelos combinados através da aproximação por mínimos quadrados (metamodelos combinados LS). Através dos metamodelos combinados LS é possível estimar a incerteza da aproximação usando qualquer tipo de metamodelagem (e não somente do tipo kriging), permitindo estimar a função de expectativa de melhora para a função objetivo. Nos experimentos computacionais anteriores em problemas de otimização sem restrições, a abordagem LSEGO mostrou-se como uma alternativa viável para conduzir otimização eficiente global usando metamodelos combinados, sem se restringir a somente um ponto adicional por ciclo de otimização iterativa. Na presente tese o algoritmo LSEGO foi extendido de modo a tratar também problemas de otimização com restrições. Os resultados de testes numéricos com problemas analíticos e de referência e também em um estudo de caso de engenharia em escala industrial mostraram-se bastante promissores e competitivos em relação aos trabalhos similares encontrados na literaturaAbstract: In this work we review and compile the results of our previous research in the fields of ensemble of metamodels and efficient global optimization (EGO). Recently we implemented LSEGO that is an approach to drive EGO algorithms, based on LS (least squares) ensemble of metamodels. By means of LS ensemble of metamodels, it is possible to estimate the uncertainty of the prediction by using any kind of model (not only kriging) and provide an estimate for the expected improvement function. In previous numerical experiments with unconstrained optimization problems, LSEGO approach has shown to be a feasible alternative to drive efficient global optimization by using multiple or ensemble of metamodels, not restricted to kriging approximation or single infill point per optimization cycles. In the present work we extended the previous LSEGO algorithm to handle constrained optimization problems as well. Some numerical experiments were performed with analytical benchmark functions and also for industry scale engineering problems with competitive resultsDoutoradoMecanica dos Sólidos e Projeto MecanicoDoutor em Engenharia Mecânic

Multiobjective global surrogate modeling, dealing with the 5-percent problem

When dealing with computationally expensive simulation codes or process measurement data, surrogate modeling methods are firmly established as facilitators for design space exploration, sensitivity analysis, visualization, prototyping and optimization. Typically the model parameter (=hyperparameter) optimization problem as part of global surrogate modeling is formulated in a single objective way. Models are generated according to a single objective (accuracy). However, this requires an engineer to determine a single accuracy target and measure upfront, which is hard to do if the behavior of the response is unknown. Likewise, the different outputs of a multi-output system are typically modeled separately by independent models. Again, a multiobjective approach would benefit the domain expert by giving information about output correlation and enabling automatic model type selection for each output dynamically. With this paper the authors attempt to increase awareness of the subtleties involved and discuss a number of solutions and applications. In particular, we present a multiobjective framework for global surrogate model generation to help tackle both problems and that is applicable in both the static and sequential design (adaptive sampling) case

Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy

Simulation is a very useful tool in the design of the part and process conditions of high pressure die casting (HPDC), due to the intrinsic complexity of this manufacturing process. Usually, physics-based models solved by finite element or finite volume methods are used, but their main drawback is the long calculation time. In order to apply optimization strategies in the design process or to implement online predictive systems, faster models are required. One solution is the use of surrogate models, also called metamodels or grey-box models. The novelty of the work presented here lies in the development of several metamodels for the HPDC process. These metamodels are based on a gradient boosting regressor technique and derived from a physics-based finite element model. The results show that the developed metamodels are able to predict with high accuracy the secondary dendrite arm spacing (SDAS) of the cast parts and, with good accuracy, the misrun risk and the shrinkage level. Results obtained in the predictions of microporosity and macroporosity, eutectic percentage, and grain density were less accurate. The metamodels were very fast (less than 1 s); therefore, they can be used for optimization activities or be integrated into online prediction systems for the HPDC industry. The case study corresponds to several parts of aluminum cast alloys, used in the automotive industry, manufactured by high-pressure die casting in a multicavity mold.This work was supported by projects OASIS and SMAPRO. The OASIS project has received funding from the European Union’s Horizon 2020 Research and Innovation Programme under Grant Agreement No 814581. The SMAPRO project has received funding from the Basque Government under the ELKARTEK Program (KK-2017/00021)

Numerical product design: Springback prediction, compensation and optimization

Numerical simulations are being deployed widely for product design. However, the accuracy of the numerical tools is not yet always sufficiently accurate and reliable. This article focuses on the current state and recent developments in different stages of product design: springback prediction, springback compensation and optimization by finite element (FE) analysis. To improve the springback prediction by FE analysis, guidelines regarding the mesh discretization are provided and a new through-thickness integration scheme for shell elements is launched. In the next stage of virtual product design the product is compensated for springback. Currently, deformations due to springback are manually compensated in the industry. Here, a procedure to automatically compensate the tool geometry, including the CAD description, is presented and it is successfully applied to an industrial automotive part. The last stage in virtual product design comprises optimization. This article presents an optimization scheme which is capable of designing optimal and robust metal forming processes efficiently