EDO - Lecture 1 - 2024

Engineering Design and Optimization
PPU191
General Engineering Optimization
Gauti Asbjörnsson
Department of Industrial and Materials Science
Chalmers University of Technology
SE-412 96 Gothenburg
e-mail: gauti@chalmers.se
Lecture objective
Show ability to master the complete development chain including modeling-

analysis-test-evaluation
Key points
Optimization formulation
Objective(s)
Modelling
Optimization algorithms
Product development
2 Division of Product Development, IMS 2024-08-26

DESIGN BUILD TEST
establish generate build models run

goals alternatives or prototypes experiments or
simulations
A1 Alternative 1
targets
meet
frame the evaluate goals
gap A2 Alternative 2 solution
problem results
current
design
A3 Alternative 3 falls short
repeat
cycle
of goals
Engineering
Design
Product Solid
Development Mechanics
http://www.mathworks.com/cmsimages/331_wl_op_main_wl_3250.jpg http://www.innovmat.eu/wp-content/uploads/2011/09/CaptureCES_sm.jpg
Optimization Materials
Techniques Selection

Why optimization?
And what does it mean?
Finding the best solution by changing variables that can

be controlled, often subjected to constraints

Why optimization?
Where does it apply?
EDO

Design optimization formulation
1. Describe the problem
2. Gather information
3. Define the design variables
4. Define the objective
5. Define the constraints
6. Modelling
7. Explore the problem
8. Solving the problem

Formulate optimization problem
Objective
function
Design variables
Inequality
Equality
Constraints
“negative null” form

• Objective(s): what do you want to minimize?

• Design variables: what can you modify?
• Parameters: what are you assuming fixed?
• Constraints: what restrictions do you have?

Objective(s): what do you want to minimize?

Design Variables
A given set of design variable values defines the system’s design, but whether
this system satisfies all the requirements is a separate question
Can be continuous or discrete.
where 𝑥 and 𝑥ҧ are lower and upper bounds on the design variables

Every real-life problem is an optimization problem!
What are your objective,

variables and constraints?

Optimization
Mindmap!
Product Applied
Development Mechanics Map out your
knowledge base from
your master program
Material Automotive
Engineering engineering and identify possible
application of
optimisation within that
… framework

Master program
Course 1 Course 2 Course 3
Aspect 1 Aspect 1
Topic 1 Topic 1 Aspect 1
Experience/interest
What is an optimal design?
Optimal product is a combination design, material and manufacturing
Design
Material Selection
Manufacturing
Most lectures
Topology Optimization
Spatially optimizes the distribution of material within a defined domain

Topography Optimization
Shape optimization that generates bead patterns and wave structures in a design space.

Why optimisation?
And what does it mean?
Managers
Plannin
g
Perspective? Manufacturing
Cost
Safety
Performance
Transformation of desires and Aerodynamics

requirements into objectives and
constraints for optimization
Engineers
Different customers
Different objectives
Reliable?
Safe?
Fast?
Cheap?

Counteracting objectives

Multi Objective Optimization
Objective 2
Attainable set
Pareto set Pareto point
Objective 1
Division of Product Development, IMS 2024-08-26

Multi Objective Optimization
Skinner and Zare-behtash. (2018) – State-of-the-art in aerodynamic shape optimisation methods

Multiple Disciplinary Optimization
EU project - The AGILE innovation project for solving realistic MDO problems

Keep it simple!
Define the system boundaries and level of abstraction

Practical problems involve a mixture of

mathematical rigor and engineering understanding
Mathematical
𝑀 equations
𝜎= Simulation models
𝐼𝑐
(FEM, CFD, etc.)
Experimental data
Define the system boundaries and level of abstraction

Design space are the available options
Feasible
Objective
Variable
Variable Objective
Solution space are the available solutions
Variable
Variable
How to handle variations?

Global Maxima
Global Minima
( − ( x +1)2 − y 2 )
x  e
z = 3(1 − x) 2 e( − x − ( y +1)2 )
− 10  − x3 − y 5  e( − x − y ) −
2 2 2
28 Division of Product Development, IMS 5  3 2024-08-26



Optimization problem classification

Optimization algorithm classification

Selection of Algorithms

Open Box – Objective maximize volume
20 cm x
x
30 cm

Starting of with little calculus

Open Box – Objective maximize volume
Define Formulate Model
Objective? min -V ( x)
max V xP V ( x) = x( H − 2 x)( L − 2 x)
Design variables? x s.t.
Constraints? H and L V ( x) = 4 x 3 − 2 x 2 ( H + L) + HLx
g1 ( x) = x − H 0
H/2-x > 0 2 V ( x) = 4 x 3 − 100 x 2 + 600 x
L/2-x > 0 g 2 ( x) = x − L  0
2
Solve
V ( x) = 4 x 3 − 100 x 2 + 600 x − B  B 2 − 4 AC
x=
2A
V '( x) = 12 x 2 − 200 x + 600 = 0
x = [3.92 12.74]
V ''( x)  0
Tablet – Objective maximize surface
Volume = 1 cm3 h

Tablet – Objective maximize surface
Objective? max A
min -A(r , h) A( x) = 2 r 2 + 2h r
Design variables? r,h r , hP
V ( x) = 2 r 2 h = 1
Constraints? s.t.
1
hi ( x) = V (r , h) − 1 = 0 h=
2 r 2
500
450
400
2
A(r ) = 2 r 2 +
350
300
r A 250
x = 0.54 200
150
2
A '(r ) = 4 r − 2
100
A ''(r )  0
50
r 0
0 1 2 3 4 5 6 7 8 9 10

Practical implementation in Matlab, Python and Ansys
function f = Obj(x)
d=x(1);
Obj n=x(2);
f= 3*d*pi/4*((Dk+2*(2*d+10))^2-Dk^2)-n*3*pi*d^2/4;
Objective
Design variables Main x0 = [90 24];
lb = [2 4];
ub = [100 24];
Parameters
[xoptw1,foptw1] = fmincon(@Obj,x0,[],[],[],[],lb,ub,@Con,options);
Constraints Con
function [c,ceq] = Con(x)
d=x(1);
n=x(2);
c(1) =Ff/(500*As)-n;
c(2) =pi*(Dk+2*5+2*d)/(6*d)-n;
c(3) =n-pi*(144+2*d)/(5+2*d);
c(4) =6-d;
c(5) =n-20;
ceq = [];

Solving an optimization problem

Optimization in product development
Ulrich, K.T., Eppinger, S.D. - Product Design & Development
Concept System-Level Testing & Production

Planning Detail Design
Development Design Refinement Ramp-Up
Wheelwright, S.C., Clark, K.B. – Revolutionizing Product Development
Knowledge Concept Prototype Pilot Manufacturing

Basic Design
Acquisition Investigation Building Production Ramp-Up
Where are we?

The Optimal Design Process

Optimization in product development
In theory design is a linear or cyclic process

Remember reality is different!

Developments in Engineering
External driving forces
Intense competition, changing customer expectation, accelerating technological change

• Shorter development cycles, better target products
Exploting product variety, sophisticated discerning customers, technical diversity

• Leverage from critical resources, increasing number of successful development projekt per engineer
Demanding customers, crowded market

• Creativity combined with total product quality, customer integrated with truly cross-functional
development process
43 Division of Product Development, IMS Wheelwright, S.C., Clark, K.B. – Revolutionizing Product Development 2024-08-26
Optimization Challenges
• Multiple objectives
• Complex systems
• Large number of variables
• Both local and global solutions
• Stochastic and deterministic results
• Computational load
• Interpretation

Optimization examples

Division of Product Development, IMS (http://www.femto.nl/) 2024-08-26




PDO P60 PhD course


In Conclusion


Next lecture(s)
Wednesday at 10.00
Applied Mechanics & Analysis tools (L2) Assignment
Workshop
EDR-Medeso
Monday at 8.00
Deadline assignment I
Introduction to Optimization (L3)
Part A
• Formulating and exploring the problem
• Chapter 1 Martins & Ning
• Chapters 3.1-3.8 Principles of Optimal Design
• Followed by Workshop 2

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Engineering Design and Optimization

General Engineering Optimization

Show ability to master the complete development chain including modeling-

2 Division of Product Development, IMS 2024-08-26

establish generate build models run

3 Division of Product Development, IMS 2024-08-26

Finding the best solution by changing variables that can

4 Division of Product Development, IMS 2024-08-26

5 Division of Product Development, IMS 2024-08-26

6 Division of Product Development, IMS 2024-08-26

“negative null” form

8 Division of Product Development, IMS 2024-08-26

• Objective(s): what do you want to minimize?

9 Division of Product Development, IMS 2024-08-26

10 Division of Product Development, IMS 2024-08-26

Can be continuous or discrete.

11 Division of Product Development, IMS 2024-08-26

What are your objective,

12 Division of Product Development, IMS 2024-08-26

13 Division of Product Development, IMS 2024-08-26

Course 1 Course 2 Course 3

Topic 1 Topic 1 Aspect 1

Optimal product is a combination design, material and manufacturing

16 Division of Product Development, IMS 2024-08-26

17 Division of Product Development, IMS 2024-08-26

Transformation of desires and Aerodynamics

19 Division of Product Development, IMS 2024-08-26

20 Division of Product Development, IMS 2024-08-26

Pareto set Pareto point

Division of Product Development, IMS 2024-08-26

Skinner and Zare-behtash. (2018) – State-of-the-art in aerodynamic shape optimisation methods

22 Division of Product Development, IMS 2024-08-26

23 Division of Product Development, IMS 2024-08-26

Define the system boundaries and level of abstraction

Practical problems involve a mixture of

Define the system boundaries and level of abstraction

Design space are the available options

Finding the best solution by changing variables that can

28 Division of Product Development, IMS 5  3 2024-08-26

Finding the best solution by changing variables that can

29 Division of Product Development, IMS 2024-08-26

30 Division of Product Development, IMS 2024-08-26

31 Division of Product Development, IMS 2024-08-26

32 Division of Product Development, IMS 2024-08-26

Open Box – Objective maximize volume

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34 Division of Product Development, IMS 2024-08-26

Define Formulate Model

Tablet – Objective maximize surface

36 Division of Product Development, IMS 2024-08-26

37 Division of Product Development, IMS 2024-08-26

38 Division of Product Development, IMS 2024-08-26

39 Division of Product Development, IMS 2024-08-26

Ulrich, K.T., Eppinger, S.D. - Product Design & Development

Concept System-Level Testing & Production

Wheelwright, S.C., Clark, K.B. – Revolutionizing Product Development

Knowledge Concept Prototype Pilot Manufacturing

Where are we?

Division of Product Development, IMS 2024-08-26