Reliability-based design optimization of 3D orthogonal woven composite automobile shock tower

2021 ◽  
pp. 002199832110476
Author(s):  
Zhao Liu ◽  
Lei Zhang ◽  
Ping Zhu ◽  
Mushi Li

Three-dimensional orthogonal woven composites are noted for their excellent mechanical properties and delamination resistance, so they are expected to have promising prospects in lightweight applications in the automobile industry. The multi-scale characteristics and inherent uncertainty of design variables pose great challenges to the optimization procedure for 3D orthogonal woven composite structures. This paper aims to propose a reliability-based design optimization method for guidance on the lightweight design of 3D orthogonal woven composite automobile shock tower, which includes design variables from material and structure. An analytical model was firstly set up to accurately predict the elastic and strength properties of composites. After that, a novel optimization procedure was established for the multi-scale reliability optimization design of composite shock tower, based on the combination of Monte Carlo reliability analysis method, Kriging surrogate model, and particle swarm optimization algorithm. According to the results, the optimized shock tower meets the requirements of structural performance and reliability, with a weight reduction of 37.83%.

2005 ◽  
Vol 297-300 ◽  
pp. 1882-1887
Author(s):  
Tae Hee Lee ◽  
Jung Hun Yoo

In practical design applications, most design variables such as thickness, diameter and material properties are not deterministic but stochastic numbers that can be represented by their mean values with variances because of various uncertainties. When the uncertainties related with design variables and manufacturing process are considered in engineering design, the specified reliability of the design can be achieved by using the so-called reliability based design optimization. Reliability based design optimization takes into account the uncertainties in the design in order to meet the user requirement of the specified reliability while seeking optimal solution. Reliability based design optimization of a real system becomes now an emerging technique to achieve reliability, robustness and safety of the design. It is, however, well known that reliability based design optimization can often have so multiple local optima that it cannot converge into the specified reliability. To overcome this difficulty, barrier function approach in reliability based design optimization is proposed in this research and feasible solution with specified reliability index is always provided if a feasible solution is available. To illustrate the proposed formulation, reliability based design optimization of a bracket design is performed. Advanced mean value method and first order reliability method are employed for reliability analysis and their optimization results are compared with reliability index approach based on the accuracy and efficiency.


Author(s):  
Heeralal Gargama ◽  
Sanjay K Chaturvedi ◽  
Awalendra K Thakur

The conventional approaches for electromagnetic shielding structures’ design, lack the incorporation of uncertainty in the design variables/parameters. In this paper, a reliability-based design optimization approach for designing electromagnetic shielding structure is proposed. The uncertainties/variability in the design variables/parameters are dealt with using the probabilistic sufficiency factor, which is a factor of safety relative to a target probability of failure. Estimation of probabilistic sufficiency factor requires performance function evaluation at every design point, which is extremely computationally intensive. The computational burden is reduced greatly by evaluating design responses only at the selected design points from the whole design space and employing artificial neural networks to approximate probabilistic sufficiency factor as a function of design variables. Subsequently, the trained artificial neural networks are used for the probabilistic sufficiency factor evaluation in the reliability-based design optimization, where optimization part is processed with the real-coded genetic algorithm. The proposed reliability-based design optimization approach is applied to design a three-layered shielding structure for a shielding effectiveness requirement of ∼40 dB, used in many industrial/commercial applications, and for ∼80 dB used in the military applications.


2011 ◽  
Vol 133 (4) ◽  
Author(s):  
Po Ting Lin ◽  
Hae Chang Gea ◽  
Yogesh Jaluria

Reliability-based design optimization (RBDO) problems have been intensively studied for many decades. Since Hasofer and Lind [1974, “Exact and Invariant Second-Moment Code Format,” J. Engrg. Mech. Div., 100(EM1), pp. 111–121] defined a measure of the second-moment reliability index, many RBDO methods utilizing the concept of reliability index have been introduced as the reliability index approach (RIA). In the RIA, reliability analysis problems are formulated to find the reliability indices for each performance constraint and the solutions are used to evaluate the failure probability. However, the traditional RIA suffers from inefficiency and convergence problems. In this paper, we revisited the definition of the reliability index and revealed the convergence problem in the traditional RIA. Furthermore, a new definition of the reliability index is proposed to correct this problem and a modified reliability index approach is developed based on this definition. The strategies to solve RBDO problems with non-normally distributed design variables by the modified RIA are also investigated. Numerical examples using both the traditional and modified RIAs are compared and discussed.


Author(s):  
Rami Mansour ◽  
Mårten Olsson

In reliability-based design optimization (RBDO), an optimal design which minimizes an objective function while satisfying a number of probabilistic constraints is found. As opposed to deterministic optimization, statistical uncertainties in design variables and design parameters have to be taken into account in the design process in order to achieve a reliable design. In the most widely used RBDO approaches, the First-Order Reliability Method (FORM) is used in the probability assessment. This involves locating the Most Probable Point (MPP) of failure, or the inverse MPP, either exactly or approximately. If exact methods are used, an optimization problem has to be solved, typically resulting in computationally expensive double loop or decoupled loop RBDO methods. On the other hand, locating the MPP approximately typically results in highly efficient single loop RBDO methods since the optimization problem is not necessary in the probability assessment. However, since all these methods are based on FORM, which in turn is based on a linearization of the deterministic constraints at the MPP, they may suffer inaccuracies associated with neglecting the nonlinearity of deterministic constraints. In a previous paper presented by the authors, the Response Surface Single Loop (RSSL) Reliability-based design optimization method was proposed. The RSSL-method takes into account the non-linearity of the deterministic constraints in the computation of the probability of failure and was therefore shown to have higher accuracy than existing RBDO methods. The RSSL-method was also shown to have high efficiency since it bypasses the concept of an MPP. In RSSL, the deterministic solution is first found by neglecting uncertainties in design variables and parameters. Thereafter quadratic response surface models are fitted to the deterministic constraints around the deterministic solution using a single set of design of experiments. The RBDO problem is thereafter solved in a single loop using a closed-form second order reliability method (SORM) which takes into account all elements of the Hessian of the quadratic constraints. In this paper, the RSSL method is used to solve the more challenging system RBDO problems where all constraints are replaced by one constraint on the system probability of failure. The probabilities of failure for the constraints are assumed independent of each other. In general, system reliability problems may be more challenging to solve since replacing all constraints by one constraint may strongly increase the non-linearity in the optimization problem. The extensively studied reliability-based design for vehicle crash-worthiness, where the provided deterministic constraints are general quadratic models describing the system in the whole region of interest, is used to demonstrate the capabilities of the RSSL method for problems with system reliability constraints.


2019 ◽  
Vol 142 (4) ◽  
Author(s):  
Leandro Luis Corso ◽  
Herbert Martins Gomes ◽  
Leandro de Freitas Spinelli ◽  
Crisley Dossin Zanrosso ◽  
Rogério José Marczak ◽  
...  

Abstract This study proposes a numerical methodology to minimize the bone mass loss in a femur with a total hip arthroplasty procedure, considering uncertainties in the material parameters and using a reliability-based design optimization (RBDO) procedure. A genetic algorithm (GA) is applied for optimization, and a three-dimensional finite element (FE) model associated with the bone remodeling procedure is proposed and described to account for the internal and external femoral bone behavior. An example of a femoral prosthesis design is presented as a basis for discussion of the proposed methodologies, and the corresponding reliability level is evaluated. Constraints on the strength of all materials and target reliability levels are inputs to the optimization model. The main prosthesis dimensions and Young modulus are the design variables. The proposed methodology is compared with a well-known deterministic optimization (DO) procedure and the results show that it is important to consider the uncertainties in this kind of problem since in this case, the a posteriori reliability may be low.


Author(s):  
Sheng Wang ◽  
Lin Hua ◽  
Xinghui Han ◽  
Zhuoyu Su

This article presents a new reliability-based design optimization procedure for the vertical vibration issues raised by a modified electric vehicle using fourth-moment polynomial standard transformation method. First, the fourth-moment polynomial standard transformation method with polynomial chaos expansion is used to obtain the reliability index of uncertain constraints in the reliability-based design optimization which is highly precise and saves computing time compared with other common methods. Next, the half-car model with nonlinear suspension parameters for the modified electric vehicle is investigated, and the response surface methodology is adopted to approximate the complex and time-consuming vertical vibration calculation to the polynomial expressions, and the approximation is validated for reliability-based design optimization results within permissible error level. Then, reliability-based design optimization results under both deterministic and uncertain load parameters are shown and analyzed. Unlike the traditional vertical vibration optimization that only considers one or several sets of load parameters, which lacks versatility, this article presents the reliability-based design optimization with uncertain load parameters which is more suitable for engineering. The results show that the proposed reliability-based design optimization procedure is an effective and efficient way to solve vertical vibration optimization problems for the modified electric vehicle, and the optimization statistics, including the maximum probability interval, can provide references for other suspension dynamical optimization.


2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Duc Hai Nguyen ◽  
Hu Wang ◽  
Fan Ye ◽  
Wei Hu

Purpose The purpose of this paper is to investigate the mechanical properties’ behaviors of woven composite cut-out structures with specific parameters. Because of the complexity of micro-scale and meso-scale structure, it is difficult to accurately predict the mechanical material behavior of woven composites. Numerical simulations are increasingly necessary for the design and optimization of test procedures for composite structures made by the woven composite. The results of the proposed method are well satisfied with the results obtained from the experiment and other studies. Moreover, parametric studies on different plates based on the stacking sequences are investigated. Design/methodology/approach A multi-scale modeling approach is suggested. Back-propagation neural networks (BPNN), radial basis function (RBF) and least square support vector regression are integrated with efficient global optimization (EGO) to reduce the weight of assigned structure. Optimization results are verified by finite element analysis. Findings Compared with other similar studies, the advantage of the suggested strategy uses homogenized properties behaviors with more complex analysis of woven composite structures. According to investigation results, it can be found that 450/−450 ply-orientation is the best buckling load value for all the cut-out shape requirements. According to the optimal results, the BPNN-EGO is the best candidate for the EGO to optimize the woven composite structures. Originality/value A multi-scale approach is used to investigate the mechanical properties of a complex woven composite material architecture. Buckling of different cut-out shapes with the same area is surveyed. According to investigation, 45°/−45° ply-orientation is the best for all cut-out shapes. Different surrogate models are integrated in EGO for optimization. The BPNN surrogate model is the best choice for EGO to optimization difficult problems of woven composite materials.


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