Design and Optimization: Status & Needs Dr. Wei Chen Associate Professor Integrated DEsign Automation Laboratory (IDEAL) Department of Mechanical Engineering Northwestern University (847)

Research Areas of IDEAL  Major Topics Robust Design & Optimization under Uncertainty (NSF) Metamodeling for Simulation-Based Design (Ford) Enterprise-Driven Multidisciplinary Decision Based Design (NSF) Model Validation (NSF) Pratt & WhitneyUS Army Ford Motorola GM Industrial Applications Alcoa, JD Power, etc.

State-of-the-Art: Efficient Probabilistic Optimization MPP  f(u 1, u 2 ) u1u1 u2u2 g=0 pdf Opt 1 Deter RA Constr n RA Constr 1 Opt 2 Deter RA Constr n RA Constr 1 Cycle 1 Cycle 2 MPP Most Probable Point (MPP) Method for Efficient Reliability Assessment Sequential Optimization and Reliability Assessment (SORA) Method pdf of g g 0gRgR Red Area = Prob(g  g R )=R Inverse MPP Strategy

State-of-the-Art: Metamodeling Techniques for Simulation Based Design CAE Model Classification of Variables Product/ Process Responses Control Factors Noise Factors A. Optimal Design of Experiments (DOE) B. Sequential Metamodeling C. Analytical Probabilistic Global Sensitivity Analysis Reduce the size of problem Identify source for variance reduction E. Probabilistic Optimization Confirmation & Metamodel Updating D. Analytical Uncertainty Propagation

Demand MARKETING TEAM CUSTOMER PREFERENCES Key Customer Attributes 1 GROUPS Engineering Attributes 2 Design Options ENGINEERING State-of-the-Art: Multidisciplinary Decision-Based Design Framework Total Lifecycle Cost ACCOUNTING 3 CORPORATE MANAGEMENT Utility (Profit) 4 Optimized Design and Price 5

Vision Rapid concurrent design of material, product, and the associated manufacturing processes, optimizing quality, costs, and performance based on high fidelity modeling spanning the whole product realization and life cycle. Product Design Process Design Material Design Concurrent/Collaborative Optimal Material, Product, and Process Design Decisions Processing Structure Properties Performance Design Driven Mapping Relation

Challenges/Research Thrusts – Seamless communication with languages/representations across material scientists, product designers, and manufacturing process engineers. – Problem decomposition/recomposition methods and modeling approach to reduce the interdependency (complexity) but to maintain the concurrency of subproblems. – Rapid design optimization methods to employ high fidelity simulation programs that capture the life cycle requirements, with the consideration of uncertainty. – Design synthesis methods to accumulate knowledge and experience that adapt to changes of design requirements. – Adaptive design framework with decision support, knowledge accumulation, and support for incorporating business and costs modeling, for multi-level users with distributed, concurrent, and collaborative access. – Model validation approach that requires the minimum amount of physical experiments and improves the confidence of using the result from optimization.