A Goal-Oriented, Sequential, Inverse Design Method for the Horizontal Integration of a Multistage Hot Rod Rolling System

2017 ◽  
Vol 139 (3) ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Kevin N. Song ◽  
Chung-Hyun Goh ◽  
Pramod Zagade ◽  
B. P. Gautham ◽  
...  
Keyword(s):  
Information Flow ◽  
Design Method ◽  
Inverse Design ◽  
Process Chain ◽  
Horizontal Integration ◽  
Rolling System ◽  
Design Variables ◽  
First Pass ◽  
Rod Rolling ◽  
Inverse Design Method

The steel manufacturing process is characterized by the requirement of expeditious development of high quality products at low cost through the effective use of available resources. Identifying solutions that meet the conflicting commercially imperative goals of such process chains is hard using traditional search techniques. The complexity in such a problem increases due to the presence of a large number of design variables, constraints and bounds, conflicting goals and the complex sequential relationships of the different stages of manufacturing. A classic example of such a manufacturing problem is the design of a rolling system for manufacturing a steel rod. This is a sequential process in which information flows from first rolling stage/pass to the last rolling pass and the decisions made at first pass influence the decisions that are made at the later passes. In this context, we define horizontal integration as the facilitation of information flow from one stage to another thereby establishing the integration of manufacturing stages to realize the end product. In this paper, we present an inverse design method based on well-established empirical models and response surface models developed through simulation experiments (finite-element based) along with the compromise decision support problem (cDSP) construct to support integrated information flow across different stages of a multistage hot rod rolling system. The method is goal-oriented because the design decisions are first made based on the end requirements identified for the process at the last rolling pass and these decisions are then passed to the preceding rolling passes following the sequential order in an inverse manner to design the entire rolling process chain to achieve the horizontal integration of stages. We illustrate the efficacy of the method by carrying out the design of a multistage rolling system. We formulate the cDSP for the second and fourth pass of a four pass rolling chain. The stages are designed by sequentially passing the design information obtained after exercising the cDSP for the last pass for different scenarios and identifying the best combination of design variables that satisfies the conflicting goals. The cDSP for the second pass helps in integrated information flow from fourth to first pass and in meeting specified goals imposed by the fourth and third passes. The end goals identified for this problem for the fourth pass are minimization of ovality (quality) of rod, maximization of throughput (productivity), and minimization of rolling load (performance and cost). The method can be instantiated for other multistage manufacturing processes such as the steel making process chain having several unit operations.

A Goal Oriented, Sequential Process Design of a Multi-Stage Hot Rod Rolling System

2016 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Kevin N. Song ◽  
Chung-Hyun Goh ◽  
Pramod Zagade ◽  
B. P. Gautham ◽  
...  
Keyword(s):  
Sequential Process ◽  
Process Chain ◽  
Rolling System ◽  
Unit Operations ◽  
Steel Making ◽  
Multi Stage ◽  
Design Variables ◽  
First Pass ◽  
Rod Rolling ◽  
Fourth Pass

The steel manufacturing process is characterized by the requirement of expeditious development of high quality products at low cost through effective and judicious use of available resources. Identifying solutions that meet the conflicting commercially imperative goals of such process chains is hard using traditional search techniques. The complexity embedded in such a problem increases due to the presence of large number of design variables, constraints and bounds, conflicting goals and the complex sequential relationships of the different stages of manufacturing. A classic example of such a manufacturing problem is the design of a rolling system for manufacturing a steel rod. This is a sequential process in which information flows from first rolling stage/pass to last rolling pass and the decisions made at first pass influence the decisions that are made at the later passes. In this paper, we present a method based on well-established empirical models and response surface models developed through simulation experiments (finite element based) along with the compromise Decision Support Problem (cDSP) construct to support integrated information flow across different stages of a multi-stage hot rod rolling system. The method is goal-oriented because the design decisions are first made based on the end requirements identified for the process at the last rolling pass and these decisions are then passed to rolling passes that precede following the sequential order in an inverse manner to design the entire rolling process chain. We illustrate the efficacy of the method by carrying out the design of a multi-stage rolling system. We formulate the cDSP for the second and fourth pass of a four pass rolling chain. The stages are designed by sequentially passing the design information obtained after exercising the cDSP for the last pass for different scenarios and identifying the best combination of design variables that satisfies the conflicting goals. The cDSP for second pass helps in integrated information flow from fourth to first pass and in meeting specified goals imposed by the fourth and third pass designed. The end goals identified for this problem for fourth pass are minimization of ovality (quality) of rod, maximization of throughput (productivity) and minimization of rolling load (performance and cost). The method can be instantiated for other multi-stage manufacturing processes such as the steel making process chain having several unit operations. In future, we plan to use the method for supporting decision workflow in steel making process by formulating cDSPs for the multiple unit operations involved and linking them as a decision network using coupled cDSPs.

An Inverse, Decision-Based Design Method for Integrated Design Exploration of Materials, Products, and Manufacturing Processes

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Vignesh Rangaraj ◽  
B. P. Gautham ◽  
Amarendra Kumar Singh ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Design Method ◽  
Integrated Design ◽  
Manufacturing Processes ◽  
Process Chain ◽  
Structure Property ◽  
Horizontal Integration ◽  
Design Exploration ◽  
Rod Rolling ◽  
Manufacturing Process Chain ◽  
Decision Based Design

A material's design revolution is underway with a focus to design the material microstructure and processing paths to achieve certain performance requirements of products. A host of manufacturing processes are involved in producing a product. The processing carried out in each process influences its final properties. To couple the material processing-structure-property-performance (PSPP) spaces, models of specific manufacturing processes must be enhanced and integrated using multiscale modeling techniques (vertical integration) and then the input and output of the various manufacturing processes must be integrated to facilitate the flow of information from one process to another (horizontal integration). Together vertical and horizontal integration allows for the decision-based design exploration of the manufacturing process chain in an inverse manner to realize the end product. In this paper, we present an inverse method to achieve the integrated design exploration of materials, products, and manufacturing processes through the vertical and horizontal integration of models. The method is supported by the concept exploration framework (CEF) to systematically explore design alternatives and generate satisficing design solutions. The efficacy of the method is illustrated for a hot rod rolling (HRR) and cooling process chain problem by exploring the processing paths and microstructure in an inverse manner to produce a rod with specific mechanical properties. The proposed method and the exploration framework are generic and support the integrated decision-based design exploration of a process chain to realize an end product by tailoring material microstructures and processing paths.

A Robust Mixing Plane Method and its Application in 3D Inverse Design of Transonic Turbine Stages

2014 ◽  
Author(s):  
Saurya Ranjan Ray ◽  
Mehrdad Zangeneh
Keyword(s):  
Design Method ◽  
Flow Direction ◽  
Flow Analysis ◽  
Inverse Design ◽  
Plane Method ◽  
Design Variables ◽  
Wide Range ◽  
Inverse Design Method ◽  
Flow Variables ◽  
Flux Conservation

A robust mixing plane method satisfying interface flux conservation, non-reflectivity and retaining interface flow variation; valid at all Mach numbers and applicable for any machine configuration is formulated and implemented in a vertex based finite volume solver for flow analysis and inverse design of turbomachinery stage configurations. The formulation is based on superposing perturbed flow variables in the form of 3D characteristics obtained along the flow direction on the exchanged mixed out average quantities at the stage interface. A condition is derived in the mixed-out averaging procedure to distinguish between the subsonic and supersonic flow conditions at the interface. Using preconditioning technique, the new functionality is demonstrated to be applicable for a wide range of interface conditions and over different machine configurations with small spatial gap across the blade rows. The method is shown to satisfy flux conservation across the interface without generating spurious oscillations in the flow field at the domain boundaries and validated against available commercial solvers. Subsequently, a blade re-design approach in a multi-row configuration is conceptualised and demonstrated by the application of the 3D inverse design method on a single stage Low Pressure Turbine. Meridional load variation, stage reaction and blade stacking angle are considered as the design variables to explore the design space. Conducting design runs at a fixed mass flow boundary condition and similar overall loading condition; the optimised configuration is shown to satisfy redistributed meridional load, providing performance improvement while maintaining a similar level of flow rate and work extraction as the baseline configuration.

scholarly journals An inverse design method for determining the optimal tributary flow into main stream in a rainstorm period

2021 ◽  
Author(s):  
Lei Liu ◽  
Huimin Chen ◽  
Xue-Yi You
Keyword(s):  
Water Quality ◽  
Design Method ◽  
Oxygen Demand ◽  
Ammonia Nitrogen ◽  
Inverse Design ◽  
Main Stream ◽  
Prediction Errors ◽  
Design Variables ◽  
Inverse Design Method ◽  
Artificial Neural Network Ann

Abstract To ensure water quality at the control cross-section of main stream (CCMS) in a rainstorm period, an inverse design method was proposed to determine the optimal discharge flow of tributary rivers. The design variables are tributary discharges and the target variables are the required concentrations of chemical oxygen demand (COD), dissolved oxygen (DO) and ammonia nitrogen (NH3-N) at CCMS. The relationship between target variables and design variables was identified using artificial neural network (ANN). The database was obtained by Environmental Fluid Dynamics Code (EFDC) and the optimal tributary discharges were obtained by genetic algorithm (GA) coupled with well-trained ANN. The results showed the following results: (a) The relative prediction errors of ANN are mostly less than 5%. (b) When the inlet flow rate is 0 m3/s, 30 m3/s, 50 m3/s, 100 m3/s and 200 m3/s, the optimization total discharges of tributaries are 5.7 m3/s, 12.5 m3/s, 18.6 m3/s, 33.4 m3/s and 61.8 m3/s, respectively. (c) Most of optimization plans satisfy entirely the water quality requirements at CCMS except a few plans, which the relative errors between optimized results and required values of COD and DO are less than 0.4% and 0.1%, respectively. The study showed that the inverse design method is efficient for determining the optimal discharges of multiple tributaries.

AN INVERSE DESIGN METHOD FOR A WING IN FULL CRUISING CONFIGURATION OF A REGIONAL AIRCRAFT VIA RANS APPROACH

2020 ◽  
Vol 51 (1) ◽  
pp. 1-13
Author(s):  
Anatoliy Longinovich Bolsunovsky ◽  
Nikolay Petrovich Buzoverya ◽  
Nikita Aleksandrovich Pushchin
Keyword(s):  
Design Method ◽  
Inverse Design ◽  
Inverse Design Method

scholarly journals Aerodynamic Inverse Design of Transonic Compressor Cascades with Stabilizing Elastic Surface Algorithm

2021 ◽  
Vol 11 (11) ◽  
pp. 4845
Author(s):  
Mohammad Hossein Noorsalehi ◽  
Mahdi Nili-Ahmadabadi ◽  
Seyed Hossein Nasrazadani ◽  
Kyung Chun Kim
Keyword(s):  
Design Method ◽  
Inverse Design ◽  
Normal Shock ◽  
Compressor Cascade ◽  
Elastic Surface ◽  
Transonic Compressor ◽  
Pressure Distributions ◽  
The Difference ◽  
Inverse Design Method ◽  
Transonic Cascade

The upgraded elastic surface algorithm (UESA) is a physical inverse design method that was recently developed for a compressor cascade with double-circular-arc blades. In this method, the blade walls are modeled as elastic Timoshenko beams that smoothly deform because of the difference between the target and current pressure distributions. Nevertheless, the UESA is completely unstable for a compressor cascade with an intense normal shock, which causes a divergence due to the high pressure difference near the shock and the displacement of shock during the geometry corrections. In this study, the UESA was stabilized for the inverse design of a compressor cascade with normal shock, with no geometrical filtration. In the new version of this method, a distribution for the elastic modulus along the Timoshenko beam was chosen to increase its stiffness near the normal shock and to control the high deformations and oscillations in this region. Furthermore, to prevent surface oscillations, nodes need to be constrained to move perpendicularly to the chord line. With these modifications, the instability and oscillation were removed through the shape modification process. Two design cases were examined to evaluate the method for a transonic cascade with normal shock. The method was also capable of finding a physical pressure distribution that was nearest to the target one.

Inverse Design of Axial-Flow Compressor Blades Using Elastic Surface Algorithm in Subsonic and Transonic Flow Regimes With Separation

2016 ◽  
Author(s):  
M. H. Noorsalehi ◽  
M. Nili-Ahamadabadi ◽  
E. Shirani ◽  
M. Safari
Keyword(s):  
Pressure Distribution ◽  
Transonic Flow ◽  
Design Method ◽  
Axial Flow ◽  
Flow Regimes ◽  
Inverse Design ◽  
Elastic Surface ◽  
Axial Flow Compressor ◽  
Inverse Design Method ◽  
Flow Compressor

In this study, a new inverse design method called Elastic Surface Algorithm (ESA) is developed and enhanced for axial-flow compressor blade design in subsonic and transonic flow regimes with separation. ESA is a physically based iterative inverse design method that uses a 2D flow analysis code to estimate the pressure distribution on the solid structure, i.e. airfoil, and a 2D solid beam finite element code to calculate the deflections due to the difference between the calculated and target pressure distributions. In order to enhance the ESA, the wall shear stress distribution, besides pressure distribution, is applied to deflect the shape of the airfoil. The enhanced method is validated through the inverse design of the rotor blade of the first stage of an axial-flow compressor in transonic viscous flow regime. In addition, some design examples are presented to prove the effectiveness and robustness of the method. The results of this study show that the enhanced Elastic Surface Algorithm is an effective inverse design method in flow regimes with separation and normal shock.

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