A systems approach to shape and topology optimisation of mechanical structures

Optimisation techniques have become more and more important as the possibility of simulating complex mechanical structures has become a reality. A common tool in the layout design of structural parts is the topology optimisation method, which finds an optimum material distribution within a given geometrical design space to best meet loading conditions and constraints. Another important method is shape optimisation, which optimises weight given parametric geometric constraints. In the case of complex shaped parts or elaborate assemblies, for example automobile body structures, shape optimisation is still hard to do; mainly due to the difficulty in translating shape design parameters into meaningful analysis models. Tools like the parametric geometry package SFE CONCEPT are designed to mitigate these issues. Nevertheless, shape methods usually cannot suggest new load path configurations, while topology methods are often confined to single parts. To overcome these limitations the authors have developed a method that combines both approaches into an Integral Shape/Topology Method (IST) that is capable of finding new optimal solutions. This is achieved by an automated optimisation loop and can be applied for both thin walled structures as well as solid 3D geometries. When optimising structures by applying IST, global optimum solutions can be determined that may not be obtained with isolated shape- or topology-optimisation methods.

Application of the strain localization CAFE model to investigate extrusion with various die shapes

Multi scale CAFE model for the prediction of initiation and propagation of the micro shear bands and shear bands in metallic materials subjected to plastic deformation is presented. The CAFE approach is the combination of the Cellular Automata (CA) and the Finite Element (FE) methods. The application of the developed CAFE model to analyze material flow during extrusion is the objective of the present work. The proposed CAFE approach is applied in this work to simulation of the extrusion with flat face and convex dies and to investigate differences in the material flow. The initial FE meshes with the set of the CA point are generated for the numerical tests and the results of the metal flow predicted by the CAFE method are presented in the paper.

An integrated approach to shape and topology optimisation of mechanical structures

In mechanical engineering, simulation and optimisation methods have become indispensable. The thesis looks into a novel way to combine shape and topology optimisation approaches. The proposed method - named IST for Integrated Shape And Topology Optimisation - proves to be beneficial for many application in the automotive and aerospace industry.

A novel bio-kinematic encoder for human exercise representation and decomposition - Part 2 : Robustness and Optimisation

Bio-kinematic characterisations of human exercises constitute dealing with parameters such as velocity, acceleration, joint angles, etc. A majority of these are measured directly from various sensors ranging from RGB cameras to inertial sensors. However, due to certain limitations associated with these sensors, such as inherent noise, filters are required to be implemented to subjugate the effect from the noise. When the two-component (trajectory shape and dynamics) bio-kinematic encoding model is being established to represent an exercise, reducing the effect from noise embedded in raw data will be important since the underlying model can be quite sensitive to noise. In this paper, we examine and compare some commonly used filters, namely least-square Gaussian filter, Savitzky-Golay filter and optimal Kalman filter, with four groups of real data collected from Microsoft Kinectc , and assert that Savitzky- Golay filter is the best one when establishing an underlying model for human exercise representation.

Optimisation of nonlinear motion cueing algorithm based on genetic algorithm

Motion cueing algorithms (MCAs) are playing a significant role in driving simulators, aiming to deliver the most accurate human sensation to the simulator drivers compared with a real vehicle driver, without exceeding the physical limitations of the simulator. This paper provides the optimisation design of an MCA for a vehicle simulator, in order to find the most suitable washout algorithm parameters, while respecting all motion platform physical limitations, and minimising human perception error between real and simulator driver. One of the main limitations of the classical washout filters is that it is attuned by the worst-case scenario tuning method. This is based on trial and error, and is effected by driving and programmers experience, making this the most significant obstacle to full motion platform utilisation. This leads to inflexibility of the structure, production of false cues and makes the resulting simulator fail to suit all circumstances. In addition, the classical method does not take minimisation of human perception error and physical constraints into account. Production of motion cues and the impact of different parameters of classical washout filters on motion cues remain inaccessible for designers for this reason. The aim of this paper is to provide an optimisation method for tuning the MCA parameters, based on nonlinear filtering and genetic algorithms. This is done by taking vestibular sensation error into account between real and simulated cases, as well as main dynamic limitations, tilt coordination and correlation coefficient. Three additional compensatory linear blocks are integrated into the MCA, to be tuned in order to modify the performance of the filters successfully. The proposed optimised MCA is implemented in MATLAB/Simulink software packages. The results generated using the proposed method show increased performance in terms of human sensation, reference shape tracking and exploiting the platform more efficiently without reaching the motion limitations.