Optimisation of laser welding of deep drawing steel for automotive applications by Machine Learning: A comparison of different techniques

Laser welding is particularly relevant in the industry thanks to its simplicity, flexibility and final quality. The industry 4.0 and sustainable manufacturing framework gives massive attention to in situ and non-destructive inspection methods to predict laser weld final quality. Literature often resorts to supervised Machine Learning approaches. However, selecting the ApTest method is non-trivial and often decision making relies on diverse and unclearly defined criteria. This work addresses this task by proposing a statistical comparison method based on nonparametric tests. The method is applied to the most relevant supervised Machine Learning approaches exploited in literature to predict laser weld quality, specifically, considering the optimisation of a new production line, hence focussing on supervised Machine Learning methods that do not require massive data set, that is, Generalized Linear Model (GLM), Gaussian Process Regression, Support Vector Machine, Classification and Regression Tree, and Genetic Algorithms. The statistical comparison is carried out to select the best-performing model, which is then exploited to optimise the production process. Additionally, an automatic process to optimise Machine Learning models and process parameters is resorted to, basing on Bayesian approaches, to reduce operator effect. This work provides quality and process engineers with a simple framework to compare Machine Learning approaches performances and select the most suitable process modelling technique

Minimization of defects generation in laser welding process of steel alloy for automotive application

Laser welding (LW) thanks to its flexibility, limited energy consumption and simple realization has a prominent role in several industrial sectors. LW process requires careful parameters' tuning to avoid generating internal defects in the microstructure or a poor weld depth, which reduce the joining mechanical strength and result in waste. This work exploits a supervised machine learning algorithm to optimize the process parameters to minimize the generated defects, while catering for design specifications and tolerances to predict defect generation probability. The work outputs a predictive quality control model to reduce non-destructive controls in the LW of aluminum for automotive applications

Application of probabilistic modeling and automated machine learning framework for high-dimensional stress field

Modern computational methods, involving highly sophisticated mathematical formulations, enable several tasks like modeling complex physical phenomenon, predicting key properties and design optimization. The higher fidelity in these computer models makes it computationally intensive to query them hundreds of times for optimization and one usually relies on a simplified model albeit at the cost of losing predictive accuracy and precision. Towards this, data-driven surrogate modeling methods have shown a lot of promise in emulating the behavior of the expensive computer models. However, a major bottleneck in such methods is the inability to deal with high input dimensionality and the need for relatively large datasets. With such problems, the input and output quantity of interest are tensors of high dimensionality. Commonly used surrogate modeling methods for such problems, suffer from requirements like high number of computational evaluations that precludes one from performing other numerical tasks like uncertainty quantification and statistical analysis. In this work, we propose an end-to-end approach that maps a high-dimensional image like input to an output of high dimensionality or its key statistics. Our approach uses two main framework that perform three steps: a) reduce the input and output from a high-dimensional space to a reduced or low-dimensional space, b) model the input-output relationship in the low-dimensional space, and c) enable the incorporation of domain-specific physical constraints as masks. In order to accomplish the task of reducing input dimensionality we leverage principal component analysis, that is coupled with two surrogate modeling methods namely: a) Bayesian hybrid modeling, and b) DeepHyper's deep neural networks. We demonstrate the applicability of the approach on a problem of a linear elastic stress field data.Comment: 17 pages, 16 figures, IDETC Conference Submissio

Data-Based Spatial and Temporal Modeling for Surface Variation Monitoring in Manufacturing.

Spatiotemporal processes exist widely in manufacturing, such as tool surface degradation in ultrasonic metal welding and surface shape progression in high-precision machining. High-resolution characterization and monitoring of spatiotemporal processes are crucial for manufacturing process control. The rapid development of 3D sensing technologies has made it possible to generate large volumes of spatiotemporal data for process characterization and monitoring. However, critical challenges exist in effectively acquiring and utilizing such spatiotemporal data in manufacturing, e.g., a high cost in the acquisition of high-resolution spatiotemporal data and a lack of systematic approaches for modeling multi-source data and monitoring spatiotemporal processes. To address these challenges, this dissertation carries out three research tasks for the development of collecting, modeling and monitoring spatiotemporal data. Specifically, (1) A novel dynamic sampling design algorithm is developed to efficiently characterize spatiotemporal processes in manufacturing. A state-space model and Kalman filter are used to predictively determine the measurement locations using a criterion considering both the prediction variance and the measurement costs. The determination of measurement locations is formulated as a binary integer programming problem, and genetic algorithm is applied for searching the optimal design. In addition, a new test statistic is proposed to monitor and update the temporal transition parameters in the spatiotemporal model. (2) A new surface modeling approach is devised to cost-effectively assess spatial surface variations by integrating an engineering model with multi-task Gaussian process (GP) learning. Surface variation is decomposed into a global trend which is induced by process variables and a zero-mean GP which shares commonality among multiple similar-but-not-identical processes. An iterative algorithm is developed to simultaneously estimate the process-specific parameters and the GP parameters. (3) A tool condition characterization and monitoring framework is developed for ultrasonic metal welding in lithium-ion battery manufacturing. The geometric progression of the tool surfaces is characterized using high-resolution spatiotemporal data. Classification algorithms are developed with monitoring features extracted from both the space and frequency domains. A novel impression measurement method is designed to effectively measure tool surfaces without the need of disassembling tools for off-line measurement.PhDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/120743/1/chshao_1.pd

Machine Learning and System Identification for Estimation in Physical Systems

In this thesis, we draw inspiration from both classical system identification and modern machine learning in order to solve estimation problems for real-world, physical systems. The main approach to estimation and learning adopted is optimization based. Concepts such as regularization will be utilized for encoding of prior knowledge and basis-function expansions will be used to add nonlinear modeling power while keeping data requirements practical.The thesis covers a wide range of applications, many inspired by applications within robotics, but also extending outside this already wide field.Usage of the proposed methods and algorithms are in many cases illustrated in the real-world applications that motivated the research.Topics covered include dynamics modeling and estimation, model-based reinforcement learning, spectral estimation, friction modeling and state estimation and calibration in robotic machining.In the work on modeling and identification of dynamics, we develop regularization strategies that allow us to incorporate prior domain knowledge into flexible, overparameterized models. We make use of classical control theory to gain insight into training and regularization while using tools from modern deep learning. A particular focus of the work is to allow use of modern methods in scenarios where gathering data is associated with a high cost.In the robotics-inspired parts of the thesis, we develop methods that are practically motivated and make sure that they are implementable also outside the research setting. We demonstrate this by performing experiments in realistic settings and providing open-source implementations of all proposed methods and algorithms

Step heating thermography supported by machine learning and simulation for internal defect size measurement in additive manufacturing

A methodology based on step-heating thermography for predicting the length dimension of small defects in additive manufacturing from temperature data measured on thermal images is proposed. Regression learners were applied with different configurations to predict the length of the defects. These algorithms were trained using large datasets generated with Finite Element Method simulations. The different predictive methods obtained were optimized using Bayesian inference. Using predictive methods generated and based on intrinsic performance results, knowing the material characteristics, the defect length can be predicted from single temperature data in defect and non-defect zone. Thus, the developed algorithms were implemented in a laboratory set-up carried out on ad-hoc manufactured parts of Nylon and polylactic acid which include induced defects with different sizes and thicknesses. Using the trained algorithm, the deviation of the predicted results for the defect size varied between 13% and 37% for PLA and between 13% and 36% for Nylon.This research has been funded by Ministry of Science and Innovation (Government of Spain) through the research project titled Fusion of nondestructive technologies and numerical simulation methods for the inspection and monitoring of joints in new materials and additive manufacturing processes (FaTIMA) with code RTI2018-099850-B-I00

Applying Bayesian Machine Learning Methods to Theoretical Surface Science

Machine learning is a rapidly evolving field in computer science with increasingly many applications to other domains. In this thesis, I present a Bayesian machine learning approach to solving a problem in theoretical surface science: calculating the preferred active site on a catalyst surface for a given adsorbate molecule. I formulate the problem as a low-dimensional objective function. I show how the objective function can be approximated into a certain confidence interval using just one iteration of the self-consistent field (SCF) loop in density functional theory (DFT). I then use Bayesian optimization to perform a global search for the solution. My approach outperforms the current state-of-the-art method, constrained minima hopping, for CO on ferric oxide by a factor of 75 to 1. This thesis is the first documented application of Bayesian optimization to surface science