Interdisciplinary design optimization of compressor blades combining low- and high-fidelity models

The optimal design of multidisciplinary systems under uncertainty involves three types of iterative analyses- multidisciplinary analyses, reliability analyses, and optimization. If these processes are carried out in a nested manner in reliability based multidisciplinary design optimization (RBMDO), the computational expense can be enormous. Computationally efficient simultaneous analysis and design (SAND) or All-AtOnce methods have been developed earlier for deterministic MDO. Single loop RBDO methods have also been developed to integrate reliability analysis and optimization in a single loop. This paper develops a novel formulation of RBMDO problems with both system and component level reliability constraints. The formulation allows for solution with a single design optimization loop by using the KKT optimality conditions of the first-order reliability method (FORM) as constraints in the design optimization along with disciplinary consistency constraints. Alternative solution processes which remove the FORM MPP’s from the decision space and many constraints from the problem are developed. The alternative solution methods are more efficient and more robust than using nonlinear programming to solve the single loop formulation. A numerical example is solved with the two proposed solution algorithms. I. Introduction In the design of multidisciplinary systems it is often necessary to make decisions under uncertainty. This requires that multidisciplinary systems modeling be integrated with uncertainty analysis and optimization. A common example of such an engineering design application would be the design of an aircraft wing under uncertain aerodynamic loading conditions, with multiple structural components with uncertain capacities, such that the entire structural system achieves a prescribed level of reliability. The problem has coupled physics, in that the pressure distribution is dependent upon the deflection, and the deflection is dependent on the pressure distribution. Such designs have been performed using multidisciplinary optimization (MDO). Other examples where MDO may be applied include electronics packaging, in which the disciplines of heat transfer and circuit analysis are coupled, the design of new types of aircraft and integrating them into an existing fleet of aircraft, and even the management of interconnected homeland infrastructures. While MDO has matured with the development of different types of algorithms for various types of problems and design organizations, there has been little work to incorporate reliability analysis into MDO. However, system and component reliabilities are often a major concern in the design of multidisciplinary systems. MDO can be computationally expensive due to the need to achieve consistency across multiple disciplinary analysis codes; each disciplinary analysis code may be computationally expensive to run. Further, the optimal design of multidisciplinary systems under uncertainty involves three types of iterative procedures- multidisciplinary analyses, reliability analyses, and optimization. The integration of these three procedures is referred to in this paper as reliability based multidisciplinary design optimization (RBMDO). If these processes are carried out simultaneously, the computational expense can be enormous. Computational savings can often be achieved with simultaneous analysis and design (SAND) or All-At-Once methods, which allow for the solution of the multidisciplinary analyses and the optimization in one single loop. Single loop RBDO methods allow for the integration of reliability analysis and optimization in a single loop. Applying SAND and single-loop RBDO together may allow for large computational savings when applied to problems in RBMDO. This paper develops a novel formulation of RBMDO problems with both system and component level reliability constraints based on the SAND method for MDO and by use of the KKT conditions of the first order reliability method (FORM). The resulting formulation may be solved as a standard nonlinear programming problem. While the single loop formulation presented in this paper is a solution of the RBMDO problem, robustness and efficiency are improved through two improved algorithms which can remove the MPP’s from the decision space, thereby significantly reducing the optimizer’s workload.

The scope of this paper is to apply a model-correction-based strategy for efficient reliability analysis of uncertain dynamical systems based on a low-fidelity (LF) model whose outcomes are corrected in a probabilistic sense to represent the more realistic outcomes of a high-fidelity (HF) model. In the model-correction approach utilized, the LF model is calibrated to the HF model close to the so-called most probable point in standard normal space, which allows a more realistic assessment of the considered complex dynamical system. Since only few expensive limit state function evaluations of the HF model are required, an efficient reliability analysis is enabled. In an application example, the LF model describes an existing single-span railway bridge modelled as simply supported Euler–Bernoulli beam subjected to moving single forces representing the axle loads of a moving train. The HF modelling approach accounts for the bridge–train interaction by modelling the passing train as mass-spring-damper system, however increasing the computational effort of the limit state function evaluations. Failure probabilities evaluated with the model-correction approach are contrasted and discussed with failure probabilities of the sophisticated bridge–train interaction model evaluated with the first-order reliability method (FORM). It is demonstrated that the efficiency of the method depends on the correlation between the LF and the HF model. A comparison of the results of FORM and the model-correction-based approach shows that the latter provides reliable failure probability prediction of the HF model while leading to a significant reduction in computational effort.

This paper presents a framework for multi-objective and multidisciplinary design optimization using highfidelity analysis tools. In this framework the aerodynamic performance is evaluated based on a Navier‐Stokes equation solver, and the structure dynamics is computed using commercially available finite element software. We employ a genetic algorithm as a robust design optimization tool to facilitate the multi-objective optimization. We also use the response surface approach to tackle the difficulties associated with the organizational complexity and computational burden inherent in the multidisciplinary optimization. The coupling between the fluid solver and structural solver is realized through a thin-plate spline interpolation algorithm. The proposed approach is then used to perform aerostructural optimization of a three-dimensional transonic compressor blade. Our numerical results show that this method can improve the existing design and reduce the required computational time by orders of magnitude.

Optimization procedure is one of the key techniques to address the computational and organizational complexities of multidisciplinary design optimization (MDO). Motivated by the idea of synthetically exploiting the advantage of multiple existing optimization procedures and meanwhile complying with the general process of satellite system design optimization in conceptual design phase, a multistage-multilevel MDO procedure is proposed in this paper by integrating multiple-discipline-feasible (MDF) and concurrent subspace optimization (CSSO), termed as MDF-CSSO. In the first stage, the approximation surrogates of high-fidelity disciplinary models are built by disciplinary specialists independently, based on which the single level optimization procedure MDF is used to quickly identify the promising region and roughly locate the optimum of the MDO problem. In the second stage, the disciplinary specialists are employed to further investigate and improve the baseline design obtained in the first stage with high-fidelity disciplinary models. CSSO is used to organize the concurrent disciplinary optimization and system coordination so as to allow disciplinary autonomy. To enhance the reliability and robustness of the design under uncertainties, the probabilistic version of MDF-CSSO (PMDF-CSSO) is developed to solve uncertainty-based optimization problems. The effectiveness of the proposed methods is verified with one MDO benchmark test and one practical satellite conceptual design optimization problem, followed by conclusion remarks and future research prospects.

Model-Based Systems Engineering (MBSE) supports the system-level design of complex products effectively. Currently, system design and optimization for complex products are two distinct processes that must be executed using different software or platforms, involving intricate data conversion processes. Applying multidisciplinary optimization to validate system optimization often necessitates remodeling the optimization objects, which is time-consuming, labor-intensive, and highly error-prone. A critical activity in systems engineering is identifying the optimal design solution for the entire system. Multidisciplinary Design Optimization (MDO) and reliability analysis are essential methods for achieving this. This paper proposes a SysML-based multidisciplinary reliability design optimization modeling method. First, by analyzing the definitions and mathematical models of multidisciplinary reliability design optimization, the SysML extension mechanism is employed to represent the optimization model based on SysML. Next, model transformation techniques are used to convert the SysML optimization model generated in the first stage into an XML description model readable by optimization solvers. Finally, the proposed method’s effectiveness is validated through an engineering case study of an in-vehicle environmental control integration system. The results demonstrate that this method fully utilizes SysML to express MDO problems, enhancing the efficiency of design optimization for complex systems. Engineers and system designers working on complex, multidisciplinary projects can particularly benefit from these advancements, as they simplify the integration of design and optimization processes, facilitating more reliable and efficient product development.

• Differentiable multi-fidelity inference: BMFIA enables gradient-based Bayesian inference for high-dimensional, non-differentiable multi-physics problems using low-fidelity model gradients. • Efficiency with minimal HF data: Accurate posterior estimates are achieved from only 100–300 HF–LF simulations with orders-of-magnitude speed-ups over HF-only inference. • Accuracy despite crude LF models: Robust posterior reconstruction is maintained even with weakly correlated or simplified low-fidelity models. High-dimensional Bayesian inverse analysis ( dim ≫ 100 ) is mostly unfeasible for computationally demanding, nonlinear physics-based high-fidelity (HF) models. Usually, the use of more efficient gradient-based inference schemes is impeded if the multi-physics models are provided by complex legacy codes. Adjoint-based derivatives are either exceedingly cumbersome to derive or nonexistent for practically relevant large-scale nonlinear and coupled multi-physics problems. Similarly, holistic automated differentiation w. r. t. primary variables of multi-physics codes is usually not yet an option and requires extensive code restructuring if not considered from the outset in the software design. This absence of differentiability further exacerbates the already present computational challenges. To overcome the existing limitations, we propose a novel inference approach called Bayesian multi-fidelity inverse analysis (BMFIA) , which leverages simpler and computationally cheaper lower-fidelity (LF) models that are designed to provide model derivatives. BMFIA learns a simple, probabilistic dependence of the LF and HF models, which is then employed in an altered likelihood formulation to statistically correct the inaccurate LF response. From a Bayesian viewpoint, this dependence represents a multi-fidelity (MF) conditional density (discriminative model). We demonstrate how this MF conditional density can be learned robustly in the small data regime from only a few HF and LF simulations (50 to 300), which would not be sufficient for naive surrogate approaches. The formulation is fully differentiable and allows the flexible design of a wide range of LF models. We demonstrate that BMFIA solves Bayesian inverse problems for scenarios that used to be prohibitive, such as finely-resolved and hence high-dimensional spatial reconstruction problems in two-dimensional Euclidean domains with static posteriors, given nonlinear and transient coupled poro-elastic media physics. We show that the resulting static MF posteriors are in excellent agreement with the (usually inaccessible) HF posteriors or ground-truth data and note that extending the framework to arbitrary three-dimensional domains is a natural and important direction for future work.

Battery thermal management system (BTMS) is a complex and highly integrated system, which is used to control the battery thermal conditions in electric vehicles (EVs). The BTMS consists of many subsystems that belong to different disciplines, which poses challenges to BTMS optimization using conventional methods. This paper develops a general variable fidelity-based multidisciplinary design optimization (MDO) architecture and optimizes the BTMS by considering different systems/disciplines from the systemic perspective. Four subsystems and/or subdisciplines are modeled, including the battery thermodynamics, fluid dynamics, structure, and lifetime model. To perform the variable fidelity-based MDO of the BTMS, two computational fluid dynamics (CFD) models with different levels of fidelity are developed. A low fidelity surrogate model and a tuned low fidelity model are also developed using an automatic surrogate model selection method, the concurrent surrogate model selection (COSMOS). An adaptive model switching (AMS) method is utilized to realize the adaptive switch between variable-fidelity models. The objectives are to maximize the battery lifetime and to minimize the battery volume, the fan's power, and the temperature difference among different cells. The results show that the variable-fidelity MDO can balance the characteristics of the low fidelity mathematical models and the computationally expensive simulations, and find the optimal solutions efficiently and accurately.

A blowout preventer (BOP) is a large valve that encases an oil well on the surface. The valve may be closed while drilling if overpressure from a reservoir causes formation fluids such as oil and natural gas to back up within the wellbore and endanger the rig. A pipe ram is one of the critical components in the BOP system, which is designed to seal around a drill pipe, restricting the flow in the annulus between the outside of the drill pipe and the wellbore. The pipe ram design family, which contains hundreds of pipe ram designs, intends to cover different configurations to suit a variety of dill pipe sizes. To assure their structural integrity under service loads, these pipe rams need to be designed to meet the stress requirements per the American Petroleum Institute (API) Specification 16A and ASME (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section VIII, Division 2. With a conventional manual design workflow, it would take a significant amount of time and effort to complete all the designs for the product family with code compliance. Therefore, a scalable solution is highly desirable for delivery of customer-needed ram blocks with much shorter lead time. MDO (Multi-Disciplinary Optimization) involves multi-code integration, CAE (Computer-Aided Engineering) workflow automation, design space exploration, and optimization. MDO-enabled, automated design optimization is becoming increasingly popular in both scientific and engineering communities. In this paper, a methodology for integration of CAD (Computer Aided Design), FEA (Finite Element Analysis), cost, and optimization packages to enable FEA automation and design optimization is presented. A BOP pipe ram is adopted as the use case. The ram block geometry was parameterized before being imported into an FEA package. The FEA workflow was automated such that once a set of geometric parameters are given, the preprocessing, solving, and postprocessing steps can be automatically completed. As part of the FEA postprocessing, stress linearization analysis per the API and ASME BPVC codes has also been automated, which had never been done in the past. A manufacturing cost analysis package can also be used to consume the parameterized geometry for automatic manufacturability assessment and cost predictions. The stress analysis and cost analysis workflows are conducted separately but also orchestrated by an MDO package. Reports that contain the analysis results are sequentially generated for various design permutations. The MDO-enabled automated design and cost analysis approach could substantially enhance efficiency and consistency in performing FEA and cost studies and producing analysis reports. It is also the backbone for automated design optimization, which could significantly improve the product performance and reliability and, meanwhile, minimize the development and product cost.

Multidisciplinary design optimization of long-range slender guided rockets considering aeroelasticity and subsidiary loads

The interaction of trailing vortices with lifting surfaces is investigated using two levels of modeling fidelity. An overset mesh-based Reynolds-averaged Navier–Stokes solver is considered as the high-fidelity computational model. A lower-fidelity model is developed by combining a vortex panel method with a propeller aerodynamic model and slipstream theory. The high-fidelity model is first validated against available experimental data obtained from the interaction of a trailing vortex generated by an upstream wing with a downstream wing. The ability of both models to represent the development of the vortex wake and integrated loads is assessed for a number of parametric configurations, including a case in which the vortex core directly impinges on the wing surface. Following this, isolated propeller and wing-mounted propeller configurations are studied. In all of these cases, the high-fidelity model is effective in predicting the details of the flow and integrated airloads. The low-fidelity model, although less accurate, is shown to accurately predict interactional air loads and performance at orders of magnitude less cost than the high-fidelity model, justifying its role as a viable tool in design and trajectory-planning applications.

History matching is a critical step within the reservoir management process to synchronize the simulation model with the production data. The history-matched model can be used for planning optimum field development and performing optimization and uncertainty quantifications. We present a novel history matching workflow based on a Bayesian framework that accommodates subsurface uncertainties. Our workflow involves three different model resolutions within the Bayesian framework: 1) a coarse low-fidelity model to update the prior range, 2) a fine low-fidelity model to represent the high-fidelity model, and 3) a high-fidelity model to re-construct the real response. The low-fidelity model is constructed by a multivariate polynomial function, while the high-fidelity model is based on the reservoir simulation model. We firstly develop a coarse low-fidelity model using a two-level Design of Experiment (DoE), which aims to provide a better prior. We secondly use Latin Hypercube Sampling (LHS) to construct the fine low-fidelity model to be deployed in the Bayesian runs, where we use the Metropolis-Hastings algorithm. Finally, the posterior is fed into the high-fidelity model to evaluate the matching quality. This work demonstrates the importance of including uncertainties in history matching. Bayesian provides a robust framework to allow uncertainty quantification within the reservoir history matching. Under uniform prior, the convergence of the Bayesian is very sensitive to the parameter ranges. When the solution is far from the mean of the parameter ranges, the Bayesian introduces bios and deviates from the observed data. Our results show that updating the prior from the coarse low-fidelity model accelerates the Bayesian convergence and improves the matching convergence. Bayesian requires a huge number of runs to produce an accurate posterior. Running the high-fidelity model multiple times is expensive. Our workflow tackles this problem by deploying a fine low-fidelity model to represent the high-fidelity model in the main runs. This fine low-fidelity model is fast to run, while it honors the physics and accuracy of the high-fidelity model. We also use ANOVA sensitivity analysis to measure the importance of each parameter. The ranking gives awareness to the significant ones that may contribute to the matching accuracy. We demonstrate our workflow for a geothermal reservoir with static and operational uncertainties. Our workflow produces accurate matching of thermal recovery factor and produced-enthalpy rate with physically-consistent posteriors. We present a novel workflow to account for uncertainty in reservoir history matching involving multi-resolution interaction. The proposed method is generic and can be readily applied within existing history-matching workflows in reservoir simulation.

In order to design a vehicle body with high strength and high stiffness, a multi-disciplinary design process should include careful consideration of multi-disciplinary design constraints to properly account for vehicle static stiffness (bending/torsional), durability, Noise/Vibration/Harshness (NVH), crash worthiness, light weight vehicle structure during the early stage of vehicle design process. With this approach, fast development of new vehicle body structures can be achieved with minimal number of iterations to match the conflicting design goals from each discipline. In the current research, a multi-disciplinary design optimization (MDO) based on a meta model is developed and refined to apply for the design of body structure. In an effort to apply the MDO for vehicle body structure, 4 phase procedures were established in the current research. In Phase I, a base model is created. In Phase II, an effect analysis is carried out. In Phase III, a meta model is created. Finally in Phase IV, using the optimization algorithm, the meta model created in Phase III is eventually refined through the process of optimization. In this research, static stiffness (bending / torsional), dynamic stiffness (1st torsion mode) were used for constrained conditions and the mass minimization was the object function for optimization.

What is Transferred and How Much is Retained? A Simulation Study of Complex Surgical Skills

Multidisciplinary design optimization (MDO) can be used in computer aided engineering (CAE) to efficiently improve and balance performance of automotive structures. However, large-scale MDO is not yet generally integrated within automotive product development due to several challenges, of which excessive computing times is the most important one. In this thesis, a metamodel-based MDO process that fits normal company organizations and CAE-based development processes is presented. The introduction of global metamodels offers means to increase computational efficiency and distribute work without implementing complicated multi-level MDO methods. The presented MDO process is proven to be efficient for thickness optimization studies with the objective to minimize mass. It can also be used for spot weld optimization if the models are prepared correctly. A comparison of different methods reveals that topology optimization, which requires less model preparation and computational effort, is an alternative if load cases involving simulations of linear systems are judged to be of major importance. A technical challenge when performing metamodel-based design optimization is lack of accuracy for metamodels representing complex responses including discontinuities, which are common in for example crashworthiness applications. The decision boundary from a support vector machine (SVM) can be used to identify the border between different types of deformation behaviour. In this thesis, this information is used to improve the accuracy of feedforward neural network metamodels. Three different approaches are tested; to split the design space and fit separate metamodels for the different regions, to add estimated guiding samples to the fitting set along the boundary before a global metamodel is fitted, and to use a special SVM-based sequential sampling method. Substantial improvements in accuracy are observed, and it is found that implementing SVM-based sequential sampling and estimated guiding samples can result in successful optimization studies for cases where more conventional methods fail.

Research on multidisciplinary fatigue optimization design method in structural design of high speed train