A hierarchical Mamdani-type fuzzy modelling approach with new training data selection and multi-objective optimisation mechanisms: A special application for the prediction of mechanical properties of alloy steels

In this paper, a systematic data-driven fuzzy modelling methodology is proposed, which allows to construct Mamdani fuzzy models considering both accuracy (precision) and transparency (interpretability) of fuzzy systems. The new methodology employs a fast hierarchical clustering algorithm to generate an initial fuzzy model efficiently; a training data selection mechanism is developed to identify appropriate and efficient data as learning samples; a high-performance Particle Swarm Optimisation (PSO) based multi-objective optimisation mechanism is developed to further improve the fuzzy model in terms of both the structure and the parameters; and a new tolerance analysis method is proposed to derive the confidence bands relating to the final elicited models. This proposed modelling approach is evaluated using two benchmark problems and is shown to outperform other modelling approaches. Furthermore, the proposed approach is successfully applied to complex high-dimensional modelling problems for manufacturing of alloy steels, using ‘real’ industrial data. These problems concern the prediction of the mechanical properties of alloy steels by correlating them with the heat treatment process conditions as well as the weight percentages of the chemical compositions

A nature-inspired multi-objective optimisation strategy based on a new reduced space searching algorithm for the design of alloy steels

In this paper, a salient search and optimisation algorithm based on a new reduced space searching strategy, is presented. This algorithm originates from an idea which relates to a simple experience when humans search for an optimal solution to a ‘real-life’ problem, i.e. when humans search for a candidate solution given a certain objective, a large area tends to be scanned first; should one succeed in finding clues in relation to the predefined objective, then the search space is greatly reduced for a more detailed search. Furthermore, this new algorithm is extended to the multi-objective optimisation case. Simulation results of optimising some challenging benchmark problems suggest that both the proposed single objective and multi-objective optimisation algorithms outperform some of the other well-known Evolutionary Algorithms (EAs). The proposed algorithms are further applied successfully to the optimal design problem of alloy steels, which aims at determining the optimal heat treatment regime and the required weight percentages for chemical composites to obtain the desired mechanical properties of steel hence minimising production costs and achieving the overarching aim of ‘right-first-time production’ of metals

Knowledge discovery for friction stir welding via data driven approaches: Part 2 – multiobjective modelling using fuzzy rule based systems

In this final part of this extensive study, a new systematic data-driven fuzzy modelling approach has been developed, taking into account both the modelling accuracy and its interpretability (transparency) as attributes. For the first time, a data-driven modelling framework has been proposed designed and implemented in order to model the intricate FSW behaviours relating to AA5083 aluminium alloy, consisting of the grain size, mechanical properties, as well as internal process properties. As a result, ‘Pareto-optimal’ predictive models have been successfully elicited which, through validations on real data for the aluminium alloy AA5083, have been shown to be accurate, transparent and generic despite the conservative number of data points used for model training and testing. Compared with analytically based methods, the proposed data-driven modelling approach provides a more effective way to construct prediction models for FSW when there is an apparent lack of fundamental process knowledge

Model fusion using fuzzy aggregation: Special applications to metal properties

To improve the modelling performance, one should either propose a new modelling methodology or make the best of existing models. In this paper, the study is concentrated on the latter solution, where a structure-free modelling paradigm is proposed. It does not rely on a fixed structure and can combine various modelling techniques in ‘symbiosis’ using a ‘master fuzzy system’. This approach is shown to be able to include the advantages of different modelling techniques altogether by requiring less training and by minimising the efforts relating optimisation of the final structure. The proposed approach is then successfully applied to the industrial problems of predicting machining induced residual stresses for aerospace alloy components as well as modelling the mechanical properties of heat-treated alloy steels, both representing complex, non-linear and multi-dimensional environments

A new holistic systems approach to the design of heat treated alloy steels using a biologically inspired multi-objective optimisation algorithm

The primary objective of this paper is to introduce a new holistic approach to the design of alloy steels based on a biologically inspired multi-objective immune optimisation algorithm. To this aim, a modified population adaptive based immune algorithm (PAIA2) and a multi-stage optimisation procedure are introduced, which facilitate a systematic and integrated fuzzy knowledge extraction process. The extracted (interpretable) fuzzy models are able to fully describe the mechanical properties of the investigated alloy steels. With such knowledge in hand, locating the ‘best’ processing parameters and the corresponding chemical compositions to achieve certain pre-defined mechanical properties of steels is possible. The research has also enabled to unravel the power of multi-objective optimisation (MOP) for automating and simplifying the design of the heat treated alloy steels and hence to achieve ‘right-first-time’ production

Knowledge discovery for friction stir welding via data driven approaches: Part 1 – correlation analyses of internal process variables and weld quality

For a comprehensive understanding towards Friction Stir Welding (FSW) which would lead to a unified approach that embodies materials other than aluminium, such as titanium and steel, it is crucial to identify the intricate correlations between the controllable process conditions, the observable internal process variables, and the characterisations of the post-weld materials. In Part I of this paper, multiple correlation analyses techniques have been developed to detect new and previously unknown correlations between the internal process variables and weld quality of aluminium alloy AA5083. Furthermore, a new exploitable weld quality indicator has, for the first time, been successfully extracted, which can provide an accurate and reliable indication of the ‘as-welded’ defects. All results relating to this work have been validated using real data obtained from a series of welding trials that utilised a new revolutionary sensory platform called ARTEMIS developed by TWI Ltd., the original inventors of the FSW process

An artificial immune systems based predictive modelling approach for the multi-objective elicitation of Mamdani fuzzy rules: a special application to modelling alloys

In this paper, a systematic multi-objective Mamdani fuzzy modeling approach is proposed, which can be viewed as an extended version of the previously proposed Singleton fuzzy modeling paradigm. A set of new back-error propagation (BEP) updating formulas are derived so that they can replace the old set developed in the singleton version. With the substitution, the extension to the multi-objective Mamdani Fuzzy Rule-Based Systems (FRBS) is almost endemic. Due to the carefully chosen output membership functions, the inference and the defuzzification methods, a closed form integral can be deducted for the defuzzification method, which ensures the efficiency of the developed Mamdani FRBS. Some important factors, such as the variable length coding scheme and the rule alignment, are also discussed. Experimental results for a real data set from the steel industry suggest that the proposed approach is capable of eliciting not only accurate but also transparent FRBS with good generalization ability

Multi-objective design optimisation of a 3D-rail stamping process using a robust multi-objective optimisation platform (RMOP)

The paper investigates the multi-objective design optimisation of a stamping process to control the final shape and the final quality using advanced high strength steels. The design problem of the stamping process is formulated to minimise the difference between the desired shape and the final geometry obtained by numerical simulation accounting elastic springback. In addition, the final product quality is maximised by improving safety zones without wrinkling, thinning, or failure. Numerical results show that the proposed methodology improves the final product quality while reduces its springback.Peer ReviewedPostprint (published version

An immune algorithm based fuzzy predictive modeling mechanism using variable length coding and multi-objective optimization allied to engineering materials processing

In this paper, a systematic multi-objective fuzzy modeling approach is proposed, which can be regarded as a three-stage modeling procedure. In the first stage, an evolutionary based clustering algorithm is developed to extract an initial fuzzy rule base from the data. Based on this model, a back-propagation algorithm with momentum terms is used to refine the initial fuzzy model. The refined model is then used to seed the initial population of an immune inspired multi-objective optimization algorithm in the third stage to obtain a set of fuzzy models with improved transparency. To tackle the problem of simultaneously optimizing the structure and parameters, a variable length coding scheme is adopted to improve the efficiency of the search. The proposed modeling approach is applied to a real data set from the steel industry. Results show that the proposed approach is capable of eliciting not only accurate but also transparent fuzzy models

Multiobjective optimal design of friction stir welding considering quality and cost issues

Because of the high complexity in microstructure evolution in friction stir welding, it becomes very difficult to design optimal welding parameters. To solve this problem, in the current paper, soft computing based data driven models are developed to provide accurate and instant predictions for the welding process, and a multiobjective optimisation approach is employed to find optimal solutions to achieve the desired quality and economic objectives. The current work studies the aluminium AA5083-O as an example, where not only weld quality and mechanical properties of a joint but also in process properties and production cost are considered as objectives in the optimal design