3D die shape optimisation for net-shape forging of aerofoil blades

This paper reports on work in developing a finite element (FE) based die shape optimisation for net-shape forging of 3D aerofoil blades for aeroengine applications. Quantitative representations of aerofoil forging tolerances were established to provide a correlation between conventional dimensional and shape specifications in forging production and those quantified in FE simulation. A new direct compensation method was proposed, employing variable weighting factors to minimise the total forging tolerances in forging optimisation computations. A surface approximation using a B-spline surface was also developed to ensure improved die surface quality for die shape representation and design. For a Ni-alloy blade test case, substantial reduction in dimensional and shape tolerances was achieved using the developed die shape optimisation system.

Rapid Implementation and Optimisation of DSP Systems on SoPC Heterogeneous Platforms

The emergence of programmable logic devices as processing platforms for digital signal processing applications poses challenges concerning rapid implementation and high level optimization of algorithms on these platforms. This paper describes Abhainn, a rapid implementation methodology and toolsuite for translating an algorithmic expression of the system to a working implementation on a heterogeneous multiprocessor/field programmable gate array platform, or a standalone system on programmable chip solution. Two particular focuses for Abhainn are the automated but configurable realisation of inter-processor communuication fabrics, and the establishment of novel dedicated hardware component design methodologies allowing algorithm level transformation for system optimization. This paper outlines the approaches employed in both these particular instances.

Evolutionary Requirements for Next-Generation Dataflow-Based FPGA System Design

The use of dataflow digital signal processing system modelling
and synthesis techniques has been a fruitful research theme for many years and has yielded many powerful rapid system synthesis and optimisation capabilities. However, recent years have seen the spectrum of languages and techniques splinter in an application specific manner, resulting in an ad-hoc design process which is increasingly dependent on the particular application under development. This poses a major problem for automated toolflows attempting to provide rapid system synthesis for a wide ranges of applications. By analysing a number of dataflow FPGA implementation case studies, this paper shows that despit ethis common traits may be found in current techniques, which fall largely into three classes. Further, it exposes limitations pertaining to their ability to adapt algorith models to implementations for different operating environments and target platforms.

Efficient modelling and optimisation of hybrid multilayered plates subject to ballistic impact

Among the key challenges present in the modelling and optimisation of composite structures against impact is the computational expense involved in setting up accurate simulations of the impact event and then performing the iterations required to optimise the designs. It is of more interest to find good designs given the limitations of the resources and time available rather than the best possible design. In this paper, low cost but sufficiently accurate finite element (FE) models were generated in LS Dyna for several experimentally characterised materials by semi-automating the modelling process and using existing material models. These models were then used by an optimisation algorithm to generate new hybrid offspring, leading to minimum weight and/or cost designs from a selection of isotropic metals, polymers and orthotropic fibre-reinforced laminates that countered a specified impact threat. Experimental validation of the optimal designs thus identified was then successfully carried out using a single stage gas gun. With sufficient computational hardware, the techniques developed in this pilot study can further utilise fine meshes, equations of state and sophisticated material models, so that optimal hybrid systems can be identified from a wide range of materials, designs and threats.

Maintaining design intent for aircraft manufacture

Design and manufacture of aircraft requires deep multi-disciplinary understanding of system behaviour. The intention of the designer can get lost due to the many changes occurring to the product and the inability of the methods and tools used to capture it. Systems engineering and optimisation tools underpin industrial approaches to design, but are not without issue. The challenge is to find a route from concept to manufacture which enables designers to maintain their original intent. The novelty in this work is that the parameterisation used to build the CAD model reflects the manufacturing capability, ensuring design intent is maintained from concept to manufacture.

Optimisation of Environment-friendly SCFRC mixes use in precast Concrete Industry

The concept of green concrete has been progressively introduced in concrete technology. At the same time, new generations of superplasticisers have become widely available and self-compacting concrete is being increasingly implemented. The aim of this research is to study the impact that different sustainable materials have on both fresh and hardened properties of Self-Compacting Fibre Reinforced Concrete (SCFRC) in order to implement their use in a precast concrete company. Different combinations of cement, mineral additions (active and inert), polypropylene fibres, superplasticisers, and aggregates have been considered. Fresh state performance has been assessed by means of: slump flow test, V-funnel, and J-ring. Concrete compressive strength values at different ages have been retained as representative of the material's performance in its hardened state. All these properties have been correlated with SCFRC proportioning parameters. The importance of interactions between mineral additions and between these and superplasticiser is emphasised, as well as the different consequences of using powders as cement replacement or as mineral additions.

Optimisation of Environment-friendly SCFRC mixes use in precast Concrete Industry (PDF Download Available). Available from: http://www.researchgate.net/publication/263304799_Optimisation_of_Environment-friendly_SCFRC_mixes_use_in_precast_Concrete_Industry [accessed Jun 5, 2015].

Taguchi optimisation approach for production of activated carbon from phosphoric acid impregnated palm kernel shell by microwave heating

Taguchi method was applied to investigate the optimal operating conditions in the preparation of activated carbon using palm kernel shell with quadruple control factors: irradiation time, microwave power, concentration of phosphoric acid as impregnation substance and impregnation ratio between acid and palm kernel shell. The best combination of the control factors as obtained by applying Taguchi method was microwave power of 800 W, irradiation time of 17 min, impregnation ratio of 2, and acid concentration of 85%. The noise factor (particle size of raw material) was considered in a separate outer array, which had no effect on the quality of the activated carbon as confirmed by t-test. Activated carbon prepared at optimum combination of control factors had high BET surface area of 1,473.55 m² g-1 and high porosity. The adsorption equilibrium and kinetic data can satisfactorily be described by the Langmuir isotherm and a pseudo-second-order kinetic model, respectively. The maximum adsorbing capacity suggested by the Langmuir model was 1000 mg g-1.

Aerofoil Optimisation Using CST Parameterisation in SU2

This paper describes an implementation of the popular method of Class-Shape Transformation for aerofoil design within SU2 software framework. To exploit the adjoint based methods for aerodynamic optimisation within the SU2, a formulation to obtain geometric sensitivities from the new parameterisation is introduced, enabling the calculation of gradients with respect to new design variables. To assess the accuracy and efficiency of the alternative approach, two transonic optimisation problems are investigated: an inviscid problem with multiple constraints and a viscous problems without any constraints. Results show the new parameterisation obtaining reliable optimums, with similar levels of
performance of the software native parameterisations.

Optimisation of Kinetic Parameters for an After-treatment Catalyst

Mathematical modelling has become an essential tool in the design of modern catalytic systems. Emissions legislation is becoming increasingly stringent, and so mathematical models of aftertreatment systems must become more accurate in order to provide confidence that a catalyst will convert pollutants over the required range of conditions. 
Automotive catalytic converter models contain several sub-models that represent processes such as mass and heat transfer, and the rates at which the reactions proceed on the surface of the precious metal. Of these sub-models, the prediction of the surface reaction rates is by far the most challenging due to the complexity of the reaction system and the large number of gas species involved. The reaction rate sub-model uses global reaction kinetics to describe the surface reaction rate of the gas species and is based on the Langmuir Hinshelwood equation further developed by Voltz et al. [1] The reactions can be modelled using the pre-exponential and activation energies of the Arrhenius equations and the inhibition terms. 
The reaction kinetic parameters of aftertreatment models are found from experimental data, where a measured light-off curve is compared against a predicted curve produced by a mathematical model. The kinetic parameters are usually manually tuned to minimize the error between the measured and predicted data. This process is most commonly long, laborious and prone to misinterpretation due to the large number of parameters and the risk of multiple sets of parameters giving acceptable fits. Moreover, the number of coefficients increases greatly with the number of reactions. Therefore, with the growing number of reactions, the task of manually tuning the coefficients is becoming increasingly challenging. 
In the presented work, the authors have developed and implemented a multi-objective genetic algorithm to automatically optimize reaction parameters in AxiSuite®, [2] a commercial aftertreatment model. The genetic algorithm was developed and expanded from the code presented by Michalewicz et al. [3] and was linked to AxiSuite using the Simulink add-on for Matlab. 
The default kinetic values stored within the AxiSuite model were used to generate a series of light-off curves under rich conditions for a number of gas species, including CO, NO, C_{3H8 and C3H6. These light-off curves were used to generate an objective function.} 
This objective function was used to generate a measure of fit for the kinetic parameters. The multi-objective genetic algorithm was subsequently used to search between specified limits to attempt to match the objective function. In total the pre-exponential factors and activation energies of ten reactions were simultaneously optimized. 
The results reported here demonstrate that, given accurate experimental data, the optimization algorithm is successful and robust in defining the correct kinetic parameters of a global kinetic model describing aftertreatment processes.

Design of Scaled Bridge Prototype for Energy Harvesting Testing

Energy harvesting from ambient vibration is a promising field, especially for applications in larger infrastructures such as bridges. These structures are more frequently monitored for damage detection because of their extended life, increased traffic load and environmental deterioration. In this regard, the possibility of sourcing the power necessary for the sensors from devices embedded in the structure, thus cutting the cost due to the management of battery replacing over the lifespan of the structure, is particularly attracting. Among others, piezoelectric devices have proven to be especially effective and easy to apply since they can be bonded to existing host structure. For these devices the energy harvesting capacity is achieved directly from the variation in the strain conditions from the surface of the structure. However these systems need to undergo significant research for optimisation of their harvesting capacity and for assessing the feasibility of application to various ranges of bridge span and load. In this regard scaled bridge prototypes can be effectively used not only to assess numerical models and studies in an inexpensive and repeatable way but also to test the electronic devices under realistic field conditions. In this paper the theory of physical similitude is applied to the design of bridge beams with embedded energy harvesting systems and health monitoring sensors. It will show both how bridge beams can be scaled in such a way to apply and test energy harvesting systems and 2) how experimental data from existing bridges can be applied to prototypes in a laboratory environment. The study will be used for assessing the reliability of the system over a train bridge case study undergoing a set load cycles and induced localised damage.

Investigation of Utilizing Single Surface Depressions in Optimization of NLF Aerofoil Design

An environment has been created for the optimisation of aerofoil profiles with inclusion of small surface features. For TS wave dominated flows, the paper examines the consequences of the addition of a depression on the aerodynamic optimisation of an NLF aerofoil, and describes the geometry definition fidelity and optimisation algorithm employed in the development process. The variables that define the depression for this optimisation investigation have been fixed, however a preliminary study is presented demonstrating the sensitivity of the flow to the depression characteristics. Solutions to the optimisation problem are then presented using both gradient-based and genetic algorithm techniques, and for accurate representation of the inclusion of small surface perturbations it is concluded that a global optimisation method is required for this type of aerofoil optimisation task due to the nature of the response surface generated. When dealing with surface features, changes in the transition onset are likely to be of a non-linear nature so it is highly critical to have an optimisation algorithm that is robust, suggesting that for this framework, gradient-based methods alone are not suited.

Investigations on the Analysis and Design of Aperiodic Frequency Selective Surfaces for Space Applications

An investigation on the design of aperiodic FSS is presented. First, an accurate yet efficient method which allows the analysis of finite sized aperiodic FSS has been developed. Subsequently, an optimisation method is implemented which optimises all the FSS elements to obtain an FSS design with an aperiodic element layout. Preliminary designs of aperiodic FSS are presented and the numerical results are discussed.

An Automated Design Framework for Assembly Task Simulation

This paper presents an automated design framework for the development of individual part forming tools for a composite stiffener. The framework uses parametrically developed design geometries for both the part and its layup tool. The framework has been developed with a functioning user interface where part / tool combinations are passed to a virtual environment for utility based assessment of their features and assemblability characteristics. The work demonstrates clear benefits in process design methods with conventional design timelines reduced from hours and days to minutes and seconds. The methods developed here were able to produce a digital mock up of a component with its associated layup tool in less than 3 minutes. The virtual environment presenting the design to the designer for interactive assembly planning was generated in 20 seconds. Challenges still exist in determining the level of reality required to provide an effective learning environment in the virtual world. Full representation of physical phenomena such as gravity, part clashes and the representation of standard build functions require further work to represent real physical phenomena more accurately.