Design of particle-reinforced polyurethane mould materials for soft tooling process using evolutionary multi-objective optimization algorithms

Polyurethane is used for making mould in soft tooling (ST) process for producing wax/plastic components. These wax components are later used as pattern in investment casting process. Due to low thermal conductivity of polyurethane, cooling time in ST process is long. To reduce the cooling time, thermal conductive fillers are incorporated into polyurethane to make composite mould material. However, addition of fillers affects various properties of the ST process, such as stiffness of the mould box, rendering flow-ability of melt mould material, etc. In the present work, multi-objective optimization of various conflicting objectives (namely maximization of equivalent thermal conductivity, minimization of effective modulus of elasticity, and minimization of equivalent viscosity) of composite material are conducted using evolutionary algorithms (EAs) in order to design particle-reinforced polyurethane composites by finding the optimal values of design parameters. The design parameters include volume fraction of filler content, size and shape factor of filler particle, etc. The Pareto-optimal front is targeted by solving the corresponding multi-objective problem using the NSGA-II procedure. Then, suitable multi-criterion decision-making techniques are employed to select one or a small set of the optimal solution(s) of design parameter(s) based on the higher level information of the ST process for industrial applications. Finally, the experimental study with a typical real industrial application demonstrates that the obtained optimal design parameters significantly reduce the cooling time in soft tooling process keeping other processing advantages.     

On the sizing of a solar thermal electricity plant for multiple objectives using evolutionary optimization

Design, implementation and operation of solar thermal electricity plants are no more an academic task, rather they have become a necessity. In this paper, we work with power industries to formulate a multi-objective optimization model and attempt to solve the resulting problem using classical as well as evolutionary optimization techniques. On a set of four objectives having complex trade-offs, our proposed procedure first finds a set of trade-off solutions showing the entire range of optimal solutions. Thereafter, the evolutionary optimization procedure is combined with a multiple criterion decision making (MCDM) approach to focus on preferred regions of the trade-off frontier. Obtained solutions are compared with a classical generating method. Eventually, a decision-maker is involved in the process and a single preferred solution is obtained in a systematic manner. Starting with generating a wide spectrum of trade-off solutions to have a global understanding of feasible solutions, then concentrating on specific preferred regions for having a more detailed understanding of preferred solutions, and then zeroing on a single preferred solution with the help of a decision-maker demonstrates the use of multi-objective optimization and decision making methodologies in practice. As a by-product, useful properties among decision variables that are common to the obtained solutions are gathered as vital knowledge for the problem. The procedures used in this paper are ready to be used to other similar real-world problem solving tasks.     

Domain-specific initial population strategy for compliant mechanisms using customized genetic algorithm

Genetic algorithms (GAs) can precisely handle the discrete structural topology optimization of single-piece elastic structures called compliant mechanisms. The initial population of these elastic structures is mostly generated by assigning the material at random. This causes disconnected or unfeasible designs and further rule-based repairing can result in representation degeneracy. However, the problem-specific initial population can affect the performance of GAs like other operators. In this paper, a domain-specific initial population strategy is developed that generates geometrically feasible structures for path generating compliant mechanisms (PGCMs). It is coupled with the elitist non-dominated sorting genetic algorithm (NSGA-II) which has been customized for structural topology optimization. The performance of initial population strategy over random initialization using customized NSGA-II is checked on single and bi-objective optimization problems. Based on the results, it is observed that the custom initialization outperforms the random initialization by dominating all the solutions and exploring larger area of posed objectives. The elastic structures obtained by solving two examples of PGCMs using domain specific initial population strategy are also presented.     

Introducing robustness in multi-objective optimization

In optimization studies including multi-objective optimization, the main focus is placed on finding the global optimum or global Pareto-optimal solutions, representing the best possible objective values. However, in practice, users may not always be interested in finding the so-called global best solutions, particularly when these solutions are quite sensitive to the variable perturbations which cannot be avoided in practice. In such cases, practitioners are interested in finding the robust solutions which are less sensitive to small perturbations in variables. Although robust optimization is dealt with in detail in single-objective evolutionary optimization studies, in this paper, we present two different robust multi-objective optimization procedures, where the emphasis is to find a robust frontier, instead of the global Pareto-optimal frontier in a problem. The first procedure is a straightforward extension of a technique used for single-objective optimization and the second procedure is a more practical approach enabling a user to set the extent of robustness desired in a problem. To demonstrate the differences between global and robust multi-objective optimization principles and the differences between the two robust optimization procedures suggested here, we develop a number of constrained and unconstrained test problems having two and three objectives and show simulation results using an evolutionary multi-objective optimization (EMO) algorithm. Finally, we also apply both robust optimization methodologies to an engineering design problem.     

A constraint consensus memetic algorithm for solving constrained optimization problems

Constraint handling is an important aspect of evolutionary constrained optimization. Currently, the mechanism used for constraint handling with evolutionary algorithms mainly assists the selection process, but not the actual search process. In this article, first a genetic algorithm is combined with a class of search methods, known as constraint consensus methods, that assist infeasible individuals to move towards the feasible region. This approach is also integrated with a memetic algorithm. The proposed algorithm is tested and analysed by solving two sets of standard benchmark problems, and the results are compared with other state-of-the-art algorithms. The comparisons show that the proposed algorithm outperforms other similar algorithms. The algorithm has also been applied to solve a practical economic load dispatch problem, where it also shows superior performance over other algorithms.     

Constrained Efficient Global Optimization for Pultrusion Process

Composite materials, as the name indicates, are composed of different materials that yield superior performance as compared to individual components. Pultrusion is one of the most cost-effective manufacturing techniques for producing fiber-reinforced composites with constant cross-sectional profiles. This obviously makes it more attractive for both researchers and practitioners to investigate the optimum process parameters. Validated computer simulations cost less as compared to physical experiments, therefore this makes them an efficient tool for numerical optimization. However, the complexity of the numerical models can still be “expensive” and forces us to use them sparingly. These relatively more complex models can be replaced with “surrogates,” which are less complex and are therefore faster to evaluate representative models. In this article, a previously validated thermochemical simulation of the pultrusion process has shortly been presented. Following this, a new constrained optimization methodology based on a well-known surrogate method, i.e., Kriging, is introduced. Next, a validation case is presented to clarify the working principles of the implementation, which also supports the upcoming main optimization test cases. This design problem involves the design of the heating die with one, two, and three heaters together with the pulling speed. The results show that the proposed methodology is very efficient in finding the optimal process and design parameters.     

Optimization of back propagation algorithm and GAS-assisted ANN models for hot metal desulphurization

Adaptive neural net (ANN) model of hot metal desulphurization is first optimized by various search methods including the golden section search and Davies-Swann-Campey methods. Logarithmic preprocessing of input data leads to a further improvement in generalization ability of the net. Genetic adaptive search (GAS) method is used to optimize the mathematical model for desulphurization and when the input data are preprocessed with this optimized model and fed into an artificial neural net, the generalization ability of the net becomes even better. Best results are obtained when using GAS to optimize the interconnection weights during the training phase, while training data are preprocessed through a mathematical model already optimized by GAS. For every process several options presented by a combination of ANN and GAS must be systematically investigated before choosing the ultimate model for predictions on shop floor.     

Network-Wide Optimal Scheduling of Transit Systems Using Genetic Algorithms

The primary objective of any transit system is to provide a better level of service to its passengers. One of the good measures of level of service is the waiting time of passengers during their journey. The waiting time consists of an initial waiting time (the time a passenger waits to board a vehicle at his or her point of origin) and a transfer time (the time a passenger waits at a transfer station while transferring from one vehicle to another). An efficient schedule minimizes the overall transfer time (TT) of passengers transferring between different routes as well as the initial waiting time (IWT) of the passengers waiting to board the vehicle at their point of origin. This paper uses genetic algorithm (GA)—a search and optimization procedure—to find optimal/near-optimal schedules of vehicles in a transit network. The main advantage of using GA is that the transit network scheduling problem can be reformulated in a manner that is computationally more efficient than the original problem. Further, the coding aspect of GA inherently takes care of most of the constraints associated with the scheduling problem. Results from a number of test problems show that GAs are able to find optimal/near-optimal schedules with minimal computational resources.     

Towards automating the discovery of certain innovative design principles through a clustering-based optimization technique

In this article, a methodology is proposed for automatically extracting innovative design principles which make a system or process (subject to conflicting objectives) optimal using its Pareto-optimal dataset. Such ‘higher knowledge’ would not only help designers to execute the system better, but also enable them to predict how changes in one variable would affect other variables if the system has to retain its optimal behaviour. This in turn would help solve other similar systems with different parameter settings easily without the need to perform a fresh optimization task. The proposed methodology uses a clustering-based optimization technique and is capable of discovering hidden functional relationships between the variables, objective and constraint functions and any other function that the designer wishes to include as a ‘basis function’. A number of engineering design problems are considered for which the mathematical structure of these explicit relationships exists and has been revealed by a previous study. A comparison with the multivariate adaptive regression splines (MARS) approach reveals the practicality of the proposed approach due to its ability to find meaningful design principles. The success of this procedure for automated innovization is highly encouraging and indicates its suitability for further development in tackling more complex design scenarios.