| 1. |
- Al Handawi, Khalil, et al.
(author)
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Design Space Exploration and Evaluation Using Margin-Based Trade-Offs
- 2024
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In: Journal of Mechanical Design - Transactions of the ASME. - 1050-0472. ; 146:6
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Journal article (peer-reviewed)abstract
- Design space exploration and margin analysis can inform critical decisions early in engineering design, helping to handle the uncertainties of early design while ensuring design performance. In practice, the complexity of many products makes such decision-making challenging. This paper addresses the challenge with a new design framework that relies on the margin value method to evaluate sets of concepts that are combinatorially generated from an enhanced function-means tree. The basis for concept comparison is the margin value in each design alternative. The margin value method is expanded to address a broad class of design problems by using surrogate models and novel metrics for evaluating different conceptual alternatives. Visualization tools are introduced to support the evaluations. The efficacy of the framework is demonstrated using the design of a structural aeroengine component involving simulation models and uncertain load specifications. Overall, this paper shows how design concepts can be compared objectively and distilled to a set of alternatives that would retain their values throughout product development.
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| 2. |
- Al Handawi, Khalil, et al.
(author)
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Optimal allocation of design margins in additive remanufacturing
- 2021
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In: Proceedings of the ASME Design Engineering Technical Conference. ; 3B-2021
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Conference paper (peer-reviewed)abstract
- Often, coping with changing requirements results in substantial overdesign, because of the ways in which design margins are allocated at the beginning of the design process. In this paper, we present a design optimization method for minimizing overdesign using additive manufacturing. We use recently defined constituents of design margins (buffer and excess) as metrics in a design optimization problem to minimize overdesign. The method can be used to obtain optimal design decisions for changing requirements. We demonstrate our method by means of a turbine rear structure design problem where changes in the temperature loads are met by depositing different types of stiffeners on the outer casing. The optimal decisions obtained by optimization minimize overdesign but ensure that requirements are met throughout the product's lifecycle.
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| 3. |
- Al Handawi, Khalil, et al.
(author)
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Optimization of Design Margins Allocation When Making Use of Additive Remanufacturing
- 2022
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In: Journal of Mechanical Design - Transactions of the ASME. - : ASME International. - 1050-0472. ; 144:1
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Journal article (peer-reviewed)abstract
- Requirement changes can result in substantial overdesign because of the way design margins are allocated at the beginning of the design process. We present a design optimization method for minimizing overdesign by making use of additive remanufacturing and recently defined constituents of design margins (buffer and excess). The method can be used to obtain a set of design decisions for different changing requirement scenarios. We demonstrate our method by means of a turbine rear structure design problem where changes in the temperature loads are met by depositing different types of stiffeners on the outer casing. The results of the case study are visualized in a tradespace, which allows for comparison between sets of optimal, flexible, and robust designs. Results show that the optimized set of design decisions balances flexibility and robustness in a cost-effective manner.
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| 4. |
- Al Handawi, Khalil, et al.
(author)
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Scalable set-based design optimization and remanufacturing for meeting changing requirements
- 2020
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In: Proceedings of the ASME Design Engineering Technical Conference. ; 11A-2020
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Conference paper (peer-reviewed)abstract
- Engineering design problems often have open-ended requirements, especially in the early stages of development. Setbased design is a paradigm for exploring, and keeping under consideration, several alternatives so that commitment to a single design can be delayed until requirements are settled. In addition, requirements may change over the lifetime of a component or a system. Novel manufacturing technologies enable designs to be remanufactured to meet changed requirements. By considering this capability during the set-based design optimization process, solutions can be scaled to meet evolving requirements and customer specifications even after commitment. Such an ability can also support a circular economy paradigm based on the return of used or discarded components and systems to working condition. We propose a set-based design methodology to obtain scalable optimal solutions that can satisfy changing requirements through remanufacturing. We first use design optimization and surrogate modeling to obtain parametric optimal designs. This set of parametric optimal designs is then reduced to scalable optimal designs by observing a set of transition rules for the manufacturing process used (additive or subtractive). The methodology is demonstrated by means of a structural aeroengine component that is remanufactured by direct energy deposition of a stiffener to meet higher loading requirements.
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| 5. |
- Gericke, Kilian, et al.
(author)
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Supporting designers : moving from method menagerie to method ecosystem
- 2020
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In: Design Science. - : Cambridge University Press. - 2053-4701. ; 6
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Journal article (peer-reviewed)abstract
- Supporting designers is one of the main motivations for design research. However, there is an ongoing debate about the ability of design research to transfer its results, which are often provided in form of design methods, into practice. This article takes the position that the transfer of design methods alone is not an appropriate indicator for assessing the impact of design research by discussing alternative pathways for impacting design practice. Impact is created by different means - first of all through the students that are trained based on the research results including design methods and tools and by the systematic way of thinking they acquired that comes along with being involved with research in this area. Despite having a considerable impact on practice, this article takes the position that the transfer of methods can be improved by moving from cultivating method menageries to facilitating the evolution of method ecosystems. It explains what is understood by a method ecosystem and discusses implications for developing future design methods and for improving existing methods. This paper takes the position that efforts on improving and maturing existing design methods should be raised to satisfy the needs of designers and to truly support them.
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| 6. |
- Handawi, Khalil Al, et al.
(author)
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Integrating additive manufacturing and repair strategies of aeroengine components in the computational multidisciplinary engineering design process
- 2018
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In: Proceedings of NordDesign: Design in the Era of Digitalization, NordDesign 2018.
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Conference paper (peer-reviewed)abstract
- This paper presents a methodology for integrating failure and lifecycle analysis related to additive manufacturing in a computational multidisciplinary engineering design framework. The specific goal of this framework is to quantify the impact of component design decisions on system-level performance in order to assess alternative manufacturing, re-manufacturing and repair strategies from both technical and business perspectives. The ultimate objective of this research is to enable such considerations in the early product design phases, where sufficient degree of freedom exists to identify component design solutions that can facilitate and accommodate different manufacturing and repair techniques that impact the entire lifecycle. The developed methodology is demonstrated by means of a jet engine component where repair strategies are included as variables in the computational design process. Numerical results confirm that these strategies can be used to trade among design attributes such as lifecycle cost, weight, and performance.
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| 7. |
- Lawand, Lydia, et al.
(author)
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A lifecycle cost-driven system dynamics approach for considering additive re-manufacturing or repair in aero-engine component design
- 2019
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In: Proceedings of the International Conference on Engineering Design, ICED. - : Cambridge University Press (CUP). - 2220-4334 .- 2220-4342. ; 2019-August, s. 1343-1352
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Conference paper (peer-reviewed)abstract
- Aero-engine component design decisions should consider re-manufacturing and/or repair strategies and their impact on lifecycle cost. Existing design approaches do not account for alternative production technologies such as the use of additive manufacturing in life extension processes. This paper presents a modeling and optimization methodology for examining the impact of design decisions in the early development stage on component lifecycle cost during the in-service phase while considering the potential use of additive manufacturing in life extension strategies. Specifically, a system dynamics model is developed to assess different end-of-life scenarios. Finally, an optimization problem is formulated and solved to minimize lifecycle cost with respect to design variables related to remanufacturing.
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| 8. |
- Lawand, Lydia, et al.
(author)
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Dynamic lifecycle cost modeling for adaptable design optimization of additively remanufactured aeroengine components
- 2020
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In: Aerospace. - : MDPI AG. - 2226-4310. ; 7:8
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Journal article (peer-reviewed)abstract
- Additive manufacturing (AM) is being used increasingly for repair and remanufacturing of aeroengine components. This enables the consideration of a design margin approach to satisfy changing requirements, in which component lifespan can be optimized for different lifecycle scenarios. This paradigm requires lifecycle cost (LCC) modeling; however, the LCC models available in the literature consider mostly the manufacturing of a component, not its repair or remanufacturing. There is thus a need for an LCC model that can consider AM for repair/remanufacturing to quantify corresponding costs and benefits. This paper presents a dynamic LCC model that estimates cumulative costs over the in-service phase and a nested design optimization problem formulation that determines the optimal component lifespan range to minimize overall cost while maximizing performance. The developed methodology is demonstrated by means of an aeroengine turbine rear structure.
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| 9. |
- Martinsson Bonde, Julian, 1992, et al.
(author)
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A similarity-assisted multi-fidelity approach to conceptual design space exploration
- 2023
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In: Computers in Industry. - 0166-3615. ; 151
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Journal article (peer-reviewed)abstract
- In conceptual design studies engineers typically utilize data-based surrogate models to enable rapid evaluation of design objectives that otherwise would be too computationally expensive and time-consuming to simulate. Due to the computationally expensive simulations, the data-based surrogate models are often trained using small sample sizes, resulting in low-fidelity models which can produce results that are not trustworthy. To mitigate this issue, a similarity-assisted design space exploration method is proposed. The similarity is measured between design points that have been evaluated through lower-fidelity data-based surrogate models and design points that have been evaluated using higher-fidelity physics-based simulations. This similarity information can then be used by design engineers to better understand the trustworthiness of the data produced by the low-fidelity surrogate models. Our numerical experiments demonstrate that such a similarity measurement can be used as an indicator of the trustworthiness of the lower-fidelity model predictions. Moreover, a second similarity metric is proposed for measuring the similarity of new designs to legacy designs, thus highlighting the potential to reuse knowledge, analysis models, and data. The proposed method is demonstrated by means of an aero-engine structural component conceptual design study. An open-source software tool developed to assist in data visualization is also presented.
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| 10. |
- Martinsson Bonde, Julian, 1992, et al.
(author)
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Exploring the Potential of Digital Twin-Driven Design of Aero-Engine Structures
- 2021
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In: Proceedings of the Design Society. - : Cambridge University Press (CUP). - 2732-527X. ; 1, s. 1521-1528
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Conference paper (peer-reviewed)abstract
- As the diversity of customer needs increases within the aerospace industry, so does the need for improved design practices to reduce quality issues downstream. When designing new products, design engineers struggle with applying tolerances to features, which often leads to expensive late design iterations. To mitigate this, one aerospace company is looking to reuse tolerance deviation data yielded during manufacturing in design. In the long term these data could provide the basis for a Digital Twin that can be used for improved product development. This article explores how data from production are used today, what issues prevents such data from being exploited in the design phase, and how they potentially could be used for design purposes in the future. To understand the current situation and identify the untapped potential of production data in design, an interview study was conducted in conjunction with a literature review. In this paper the current situation and primary barriers are presented and a possible path for further research and development is suggested.
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