Stochastic analysis and robust optimization for a deck lid inner panel stamping

FE-simulation and optimization are widely used in the stamping process to improve design quality and shorten development cycle. However, the current simulation and optimization may lead to non-robust results due to not considering the variation of material and process parameters. In this study, a novel stochastic analysis and robust optimization approach is proposed to improve the stamping robustness, where the uncertainties are involved to reflect manufacturing reality. A meta-model based stochastic analysis method is developed, where FE-simulation, uniform design and response surface methodology (RSM) are used to construct meta-model, based on which Monte-Carlo simulation is performed to predict the influence of input parameters variation on the final product quality. By applying the stochastic analysis, uniform design and RSM, the mean and the standard deviation (SD) of product quality are calculated as functions of the controllable process parameters. The robust optimization model composed of mean and SD is constructed and solved, the result of which is compared with the deterministic one to show its advantages. It is demonstrated that the product quality variations are reduced significantly, and quality targets (reject rate) are achieved under the robust optimal solution. The developed approach offers rapid and reliable results for engineers to deal with potential stamping problems during the early phase of product and tooling design, saving more time and resources.     

Stochastic Subset Optimization for optimal reliability problems

Reliability-based design of a system often requires the minimization of the probability of system failure over the admissible space for the design variables. For complex systems this probability can rarely be evaluated analytically and so it is often calculated using stochastic simulation techniques, which involve an unavoidable estimation error and significant computational cost. These features make efficient reliability-based optimal design a challenging task. A new method called Stochastic Subset Optimization (SSO) is proposed here for iteratively identifying sub-regions for the optimal design variables within the original design space. An augmented reliability problem is formulated where the design variables are artificially considered as uncertain and Markov Chain Monte Carlo techniques are implemented in order to simulate samples of them that lead to system failure. In each iteration, a set with high likelihood of containing the optimal design parameters is identified using a single reliability analysis. Statistical properties for the identification and stopping criteria for the iterative approach are discussed. For problems that are characterized by small sensitivity around the optimal design choice, a combination of SSO with other optimization algorithms is proposed for enhanced overall efficiency.     

A Stochastic Simplex Approximate Gradient (StoSAG) for optimization under uncertainty

We consider a technique to estimate an approximate gradient using an ensemble of randomly chosen control vectors, known as Ensemble Optimization (EnOpt) in the oil and gas reservoir simulation community. In particular, we address how to obtain accurate approximate gradients when the underlying numerical models contain uncertain parameters because of geological uncertainties. In that case, ‘robust optimization’ is performed by optimizing the expected value of the objective function over an ensemble of geological models. In earlier publications, based on the pioneering work of Chen et al. (2009), it has been suggested that a straightforward one‐to‐one combination of random control vectors and random geological models is capable of generating sufficiently accurate approximate gradients. However, this form of EnOpt does not always yield satisfactory results. In a recent article, Fonseca et al. (2015) formulate a modified EnOpt algorithm, referred to here as a Stochastic Simplex Approximate Gradient (StoSAG; in earlier publications referred to as ‘modified robust EnOpt’) and show, via computational experiments, that StoSAG generally yields significantly better gradient approximations than the standard EnOpt algorithm. Here, we provide theoretical arguments to show why StoSAG is superior to EnOpt. © 2016 The Authors. International Journal for Numerical Methods in Engineering Published by John Wiley & Sons, Ltd.     

Evolutionary topology optimization using design space adjustment based on fixed grid

Design space optimization for topology based on fixed grid is proposed and its superiority to conventional topology optimization is shown. In the conventional topology optimization, the design domain is fixed. It is, however, desirable to make the design domain evolve into a better one during optimization process by increasing or decreasing the number of design pixels or variables, which we call design space optimization. A breakthrough in obtaining sensitivities when design space expands has been made recently with necessary mathematical background, but due to coupling effect and others, sensitivity results have not been satisfactory. Three innovative implementations are developed in this paper. Firstly, the proper characteristics of artificial material are defined. The second one is to decouple neighbouring elements for exact design space sensitivities. The previous design space optimization has been tedious because only one layer can be added. So, the third innovation is a new expansion strategy with multi‐layers based on design space sensitivities. As a result, the proposed evolutionary method can get an optimum much faster than ever before especially for large‐scale problems. It is also conjectured that this gives higher probability of getting the global optimum, as confirmed by numerical examples. Copyright © 2005 John Wiley & Sons, Ltd.     

A new optimization algorithm for solving complex constrained design optimization problems

This article presents the performance of a very recently proposed Jaya algorithm on a class of constrained design optimization problems. The distinct feature of this algorithm is that it does not have any algorithm-specific control parameters and hence the burden of tuning the control parameters is minimized. The performance of the proposed Jaya algorithm is tested on 21 benchmark problems related to constrained design optimization. In addition to the 21 benchmark problems, the performance of the algorithm is investigated on four constrained mechanical design problems, i.e. robot gripper, multiple disc clutch brake, hydrostatic thrust bearing and rolling element bearing. The computational results reveal that the Jaya algorithm is superior to or competitive with other optimization algorithms for the problems considered.     

Sparse Grid Collocation Method for an Optimal Control Problem Involving a Stochastic Partial Differential Equation with Random Inputs

In this article, we propose and analyse a sparse grid collocation method to solve an optimal control problem involving an elliptic partial differential equation with random coefficients and forcing terms. The input data are assumed to be dependent on a finite number of random variables. We prove that an optimal solution exists, and derive an optimality system. A Galerkin approximation in physical space and a sparse grid collocation in the probability space is used. Error estimates for a fully discrete solution using an appropriate norm are provided, and we analyse the computational efficiency. Computational evidence complements the present theory, to show the effectiveness of our stochastic collocation method.     

Adaptive sparse grid based HOPGD: Toward a nonintrusive strategy for constructing space‐time welding computational vademecum

Simulation‐based engineering usually needs the construction of computational vademecum to take into account the multiparametric aspect. One example concerns the optimization and inverse identification problems encountered in welding processes. This paper presents a nonintrusive a posteriori strategy for constructing quasi‐optimal space‐time computational vademecum using the higher‐order proper generalized decomposition method. Contrary to conventional tensor decomposition methods, based on full grids (eg, parallel factor analysis/higher‐order singular value decomposition), the proposed method is adapted to sparse grids, which allows an efficient adaptive sampling in the multidimensional parameter space. In addition, a residual‐based accelerator is proposed to accelerate the higher‐order proper generalized decomposition procedure for the optimal aspect of computational vademecum. Based on a simplified welding model, different examples of computational vademecum of dimension up to 6, taking into account both geometry and material parameters, are presented. These vademecums lead to real‐time parametric solutions and can serve as handbook for engineers to deal with optimization, identification, or other problems related to repetitive task.     

Shape optimization for radar cross sections by a gradient method

A gradient method for optimization of shape and materials for radar cross section (RCS) reduction is derived from Maxwell's equations. The method uses the adjoint problem and finds the derivatives of the RCS with respect to all design parameters from a single solution of the scattering problem. The method is tested in two-dimensional test problems to minimize the RCS in specified angular intervals at a single frequency, and finds configurations with strongly reduced RCS in a small number of iterations. In the absence of other constraints, the optimal shapes of perfectly electrically conducting (PEC) scatterers have sharp corners pointing in the directions where the RCS is minimized and shapes optimized at a single or small number of frequencies exhibit corrugations with about half the wavelength of the incident wave. The corrugations can be suppressed by means of penalty functions, and this gives only moderate increases of the RCS. After such regularization, the optimal shapes agree well with expectations from geometrical optics; they have almost flat surfaces whose normals lie outside the intervals chosen for RCS optimization, and sharp edges at locations where the surface normal points into the intervals in which the RCS is minimized. Shape optimization of PEC wing profiles aiming at both good aerodynamical properties and low RCS show give conflicting requirements on the shape. Copyright © 2004 John Wiley & Sons, Ltd.     

A strength-based multiple cutout optimization in composite plates using fixed grid finite element method

The design of interior cutouts in laminated composite panels is of great importance in aerospace, automobile and structural engineering. Based on the Tsai–Hill failure criterion of the first ply, this paper presents a newly developed Fixed (FG) Grid Evolutionary Structural Optimization (ESO) method to explore shape optimization of multiple cutouts in composite structures. Different design cases with varying number of cutouts, ply orientations and lay-up configurations are taken into account in this study. The examples demonstrate that the optimal boundaries produced by FG ESO are much smoother than those by traditional ESO. The results show the remarkable effects of different opening numbers and various lay-up configurations on resulting optimal shapes. The paper also provides an in-depth observation in the interactive influence of the adjacent cutouts on the optimal shapes.     

Evolutionary topology optimization using the extended finite element method and isolines

This study presents a new algorithm for structural topological optimization of two-dimensional continuum structures by combining the extended finite element method (X-FEM) with an evolutionary optimization algorithm. Taking advantage of an isoline design approach for boundary representation in a fixed grid domain, X-FEM can be implemented to improve the accuracy of finite element solutions on the boundary during the optimization process. Although this approach does not use any remeshing or moving mesh algorithms, final topologies have smooth and clearly defined boundaries which need no further interpretation. Numerical comparisons of the converged solutions with standard bi-directional evolutionary structural optimization solutions show the efficiency of the proposed method, and comparison with the converged solutions using MSC NASTRAN confirms the high accuracy of this method.     

Stochastic user equilibrium model with a tradable credit scheme and application in maximizing network reserve capacity

The tradable credit scheme (TCS) outperforms congestion pricing in terms of social equity and revenue neutrality, apart from the same perfect performance on congestion mitigation. This article investigates the effectiveness and efficiency of TCS on enhancing transportation network capacity in a stochastic user equilibrium (SUE) modelling framework. First, the SUE and credit market equilibrium conditions are presented; then an equivalent general SUE model with TCS is established by virtue of two constructed functions, which can be further simplified under a specific probability distribution. To enhance the network capacity by utilizing TCS, a bi-level mathematical programming model is established for the optimal TCS design problem, with the upper level optimization objective maximizing network reserve capacity and lower level being the proposed SUE model. The heuristic sensitivity analysis-based algorithm is developed to solve the bi-level model. Three numerical examples are provided to illustrate the improvement effect of TCS on the network in different scenarios.     

Evolutionary optimization in thermoelastic problems using the boundary element method

 The paper is devoted to application of evolutionary algorithms and the boundary element method to shape optimization of structures for various thermomechanical criteria, inverse problems of finding an optimal distribution of temperature on the boundary and identification of unknown boundary. Design variables are specified by Bezier curves. Several numerical examples of evolutionary computation are presented. Received 6 November 2000     

Design space optimization using a numerical design continuation method

A generalized optimization problem in which design space is also a design to be found is defined and a numerical implementation method is proposed. In conventional optimization, only a portion of structural parameters is designated as design variables while the remaining set of other parameters related to the design space are often taken for granted. A design space is specified by the number of design variables, and the layout or configuration. To solve this type of design space problems, a simple initial design space is selected and gradually improved while the usual design variables are being optimized. To make the design space evolve into a better one, one may increase the number of design variables, but, in this transition, there are discontinuities in the objective and constraint functions. Accordingly, the sensitivity analysis methods based on continuity will not apply to this discontinuous stage. To overcome the difficulties, a numerical continuation scheme is proposed based on a new concept of a pivot phase design space. Two new categories of structural optimization problems are formulated and concrete examples shown. Copyright © 2001 John Wiley & Sons, Ltd.     

A robust cellular manufacturing system design for dynamic part population using a genetic algorithm

As changing conditions prevail in the manufacturing environment, the design of cellular manufacturing systems, which involves the formation of part families and machine cells, is difficult. This is due to the fact that the machines need to be relocated as per the requirements if adaptive designs are used. This paper presents a new approach (robust design) for forming part families and machine cells, which can handle all the changes in demands and product mixes without any relocations. This method suggests fixed machine cells for the dynamic nature of the production environment by considering a multi-period forecast of product mix and demand. A genetic algorithm based solution procedure is adopted to solve the problem. The results thus obtained were compared with the adaptive design proposed by Wicks and Reasor (1999 Wicks, EM and Reasor, RJ. 1999. Designing cellular manufacturing systems with dynamic part populations. IIE Trans., 31: 11–20. [Taylor &; Francis Online], [Web of Science ®] , [Google Scholar]). It is found that the robust design performs better than the adaptive design for the problems attempted.     

Robust topology optimization of continuum structures with loading uncertainty using a perturbation method

An approach for the robust topology optimization (RTO) of continuum structures with loading uncertainty is investigated. The loading uncertainties are quantified using the second order Taylor series expansion of uncertain loading magnitudes and directions, and then the response statistic mean and standard deviation of compliance are calculated using the uncertain perturbation propagation method. A robust design Lagrange function considering the compliance objective and finite element constraints is developed, and a sensitivity analysis is performed to calculate the Lagrange coefficients. The Lagrange objective function is optimized using the modified solid isotropic material with penalization (SIMP) algorithm; thus, the optimum material distribution under loading uncertainty is acquired. The proposed methodology is used for the RTO of two examples, revealing its efficiency under both concentrated and distributed uncertain loadings. The accuracy of the results is verified by comparison with similar cases found in the literature where a different modelling approach was used.     

Application of a territorial-based filtering algorithm in turbomachinery blade design optimization

A territorial-based filtering algorithm (TBFA) is proposed as an integration tool in a multi-level design optimization methodology. The design evaluation burden is split between low- and high-cost levels in order to properly balance the cost and required accuracy in different design stages, based on the characteristics and requirements of the case at hand. TBFA is in charge of connecting those levels by selecting a given number of geometrically different promising solutions from the low-cost level to be evaluated in the high-cost level. Two test case studies, a Francis runner and a transonic fan rotor, have demonstrated the robustness and functionality of TBFA in real industrial optimization problems.     

Simultaneous variable selection and outlier detection using a robust genetic algorithm

Given a dataset in which it is known that all spectra are representative, without error, and have matching accurate reference values, there are many tools which exist to determine the best set of variables to use for constructing an inverse model, such as partial least squares (PLS). Likewise, given that the best variables are known a priori, there are many tools that can be used to determine if any samples are outliers, either due to inaccurate reference values, or due to invalid spectra. However, in many real-world situations, the reference values contain error and the spectra are imperfect. In this situation, it is not always possible to determine either the best subset of samples or the best subset of variables. This paper presents a new technique for combining a robust outlier determination method with a genetic algorithm optimized for spectral variable selection. No assumptions are made as to the optimum set of variables or as to the amount and structure of the errors present in either the predictor (X) or predictand (Y) variables. The technique is best suited for datasets which contain redundant information, i.e., datasets from designed experiments with no replicates may not produce optimum results, as the experimental design implicitly assumes there are no outlier data.     

Shape optimization of preform tools in forging of aerofoil using a metamodel-assisted multi-island genetic algorithm

Preform design plays an important role in improving the material flow, mechanical properties and reducing defects for forgings with complex shapes. In this paper, a study on shape optimization of preform tools in forging of an airfoil is carried out based on a multi-island genetic algorithm combined with a metamodel technique. An optimal Latin hypercube sampling technique is employed for sampling with the expected coverage of parameter space. Finite element (FE) simulations of multistep forging processes are implemented to obtain the objective function values for evaluating the forging qualities. For facilitating the optimization process, a radial basis function surrogate model is established to predict the responses of the hot forging process to the variation of the preform tool shape. In consideration of the compromise between different optimal objectives, a set of Pareto-optimal solutions are identified by the suggested genetic algorithm to provide more selections. Finally, according to the proposed fitness function, the best solution of multi-objective optimization on the Pareto front is confirmed and the corresponding preform tool shape proves optimal performances with substantially improved forging qualities via FE validation.     

Design optimization of steel frames using an enhanced firefly algorithm

Mathematical modelling of real-world-sized steel frames under the Load and Resistance Factor Design–American Institute of Steel Construction (LRFD-AISC) steel design code provisions, where the steel profiles for the members are selected from a table of steel sections, turns out to be a discrete nonlinear programming problem. Finding the optimum design of such design optimization problems using classical optimization techniques is difficult. Metaheuristic algorithms provide an alternative way of solving such problems. The firefly algorithm (FFA) belongs to the swarm intelligence group of metaheuristics. The standard FFA has the drawback of being caught up in local optima in large-sized steel frame design problems. This study attempts to enhance the performance of the FFA by suggesting two new expressions for the attractiveness and randomness parameters of the algorithm. Two real-world-sized design examples are designed by the enhanced FFA and its performance is compared with standard FFA as well as with particle swarm and cuckoo search algorithms.