1. 2/13/2014 1 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Dr. Achille Messac Multidisciplinary Design and Optimization Laboratory Mechanical, and Aeronautical Engineering Department Rensselaer Polytechnic Institute Multidisciplinary Design Optimization as a Powerful Risk Mitigation Tool

2. 2/13/2014 2 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Presentation Outline 1- Multidisciplinary Design Optimization What is it? A bit of history… 2- Aerospace and other MDO Applications 3- Multiobjective reality -- Physical Programming 4- Venturing into the nondeterministic environment of RISK – The role of MDO 5- Optimization in Conceptual Design 6- Concluding Remark

3. 2/13/2014 3 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development From Early Timid Optimization Applications to MDO From 50s to 70s, engineering optimization is - Primarily Uni-disciplinary Aerospace >> Structure – min. mass - Computationally Challenged - Of Timid Problem Scope - Heavily reliant on the defective MO method -- weighted sum

4. 2/13/2014 4 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development From Early Timid Optimization Applications to MDO -- Cont. In early to mid eighties - Computers become faster, and start decreasing in cost - Optimal Control grows in popularity - Large Space Structures research grows - Concurrent Engineering becomes a cherished word - Bi-disciplinary optimization: Control-Structure (Messac, Hale) - NASA, Air Force, and JPL initiate MDO, CSI programs - Government financial resources relatively abundant (human, computer – however slow) - First Pre-MDO conference is held at Langley (Sobieski – 1984)

5. 2/13/2014 5 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development From Early Timid Optimization Applications to MDO -- Cont. Mid 80s to Mid 90s - Computers are much faster and cheaper - AIAA MDO TC is born (Transition from Bi- to Multi-disciplinary) - MDO is still largely Deterministic - MDO is still implemented in later stages of design Not at Conceptual Design Stage - MDO is still largely addressing traditional disciplines Aero, Structure, Control – Neglecting Cost, Management, etc. While… - MDOs popularity and use grows many-fold (e.g. GE heating element) - MDO research enjoys strong international growth - MA&O Conference grows more and more successful

6. 2/13/2014 6 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development From Early Timid Optimization Applications to MDO -- Cont. Mid 90s to Present -MDO is still implemented in later stages of design Not at Conceptual Design Stage -- New Conceptual Design optimization method emerged (s-Pareto based Conceptual Design – Mattson-Messac) -Optimization is still often used using the defective weighted sum paradigm - Computer cost and speed are dramatically reduced - MDO grows within government AND industry -MDO begins to address non-traditional disciplines Cost, Management, Manufacturability, Profit, Safety, Risk, etc. - MDO becomes more appropriately treated as Multiobjective - MA&O Conference continues to prosper: 2002 Atlanta; Sept. 2004 Near Saratoga Springs NY

7. 2/13/2014 7 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Multidisciplinary Design Optimization (MDO) CFD Structures Performance Aero Loads Deformations Mach Number Str. Weight Aero Loads TOGW Design space discipline 1 Design space discipline 2 Design Variables Performance Multidisciplinary Optimal Design Discipline 1 Optimum Feasible Design Space Suboptimal Design Conventional Trades MDO Search Discipline 2 Optimum Effective Integration of Individual Disciplines/Subsystems to Capture the Interactions Novel Solution Procedures to Enable Improved System Solutions: - Account for Interdisciplinary Couplings & Integrated Product Team (IPT) settings. MDO = { Design Optimization, Design Exploration, Cross-Attribute Optimization, InterDisciplinary Optimization, System Synthesis }

8. 2/13/2014 8 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development NVH Frontal Crash Offset Crash Roof Crush Minimize: Vehicle Weight Subject to:NVH design targets Frequency Bending Displacement Torsion Displacement Frontal crash design targets Dummy HIC Dummy Chest G Probability of severe injury Roof crush design targets Maximum resistant force 50% Frontal Offset crash design targets Intrusion Side Impact design targets Displacements Viscous Criterion Safety Ford-SGI - Vehicle System MDO Project HPC/MDO for NVH & Safety on the Origin 3800 Side Impact Everything influences everything else!

9. 2/13/2014 9 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Aerodynamics Propulsion Controls Hydraulics Avionics Electrical system Fuel system Landing gear Structural optimization is at MDO roots AIRFRAME STRUCTURE In Vehicle Everything Couples to Structure

10. 2/13/2014 10 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Car Body Optimization for Noise, Vibration, Harshness, and Crash Vehicle Roof Crush is a federally mandated requirement to enhance passenger safety during a rollover event. NVH must be constrained for passengers comfort Modified NVH Model with a Square Ram to Perform Roof Crush as specified by regulations Finite Element Model of 390,000+ dof, 6000+ boundary conditions; 20 design variables Optimization executed using Response Surface approximations to crash analysis and sensitivity-based approximations to NVH Implemented on a computer with 256 processors Single processor computer would need 257 days to do this optimization It was condensed to 1 day on the multiprocessor machine. Courtesy: Ford Motor Co./R-J. Yang

11. 2/13/2014 11 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Air Borne Laser System Design BMC 4 I Boeing 8-10 March Beam Control System Turret Assembly Large Optics Four Axis gimbals Transfer optics Beam Transfer Assembly Sensor Suite Active Mirrors Illuminators Electronics Software/Processors 747F Aircraft - BoeingBoeing CDR 29 Feb - 3 Mar Chemical Oxygen Iodine Laser (COIL) TRW 21-23 March System Level Design Boeing CDR 25-27 April 12

12. 2/13/2014 12 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Supersonic Business Jet Test Case

13. 2/13/2014 13 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development MDO necessary to protect very small payload margin Massively computational problem Candidate MDO method : design data bases for subsystems and disciplines precomputed off-line using multiprocessor computing Examples of applications that will need all that Configuration A Configuration B Courtesy: NASA LRC/Troutman

14. 2/13/2014 14 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development u Obtaining an effective objective function is difficult in practice. u Weighted-Sum (WS) method for optimization has its inherent significant drawbacks. It is incapable of capturing a large class of potentially desirable Pareto solutions. It is also the most popular! u Compromise Programming (CP) method can be used to generate a complete set of efficient solutions, but its reliance on meaningless weights is a serious problem. Pareto... u Etc. Prevailing Practice

15. 2/13/2014 15 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Obj. Fun. Line Optimal Solution Using Weighted-Sum

16. 2/13/2014 16 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Pareto Solutions Using Weighted-Sum

17. 2/13/2014 17 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Obj. Fun. Line Weighted-Sum in Non-Convex Pareto Frontiers

18. 2/13/2014 18 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Obj. Fun. Line Weighted Compromise Programming for Non-Convex Pareto Frontiers

19. 2/13/2014 19 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Quantify Preference for Each Design Metric Ex: Mass of Beam Highly Desirable< 250 (kg) Desirable 250 - 275 Tolerable275 - 300 Undesirable300 - 325 Highly Undesirable 325 - 350 Unacceptable > 350 Physical Programming (cont.)

20. 2/13/2014 20 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Expressing Designer Preference During the Optimization Process

21. 2/13/2014 21 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Behavior of the PP Class Function for Change in Preferences

22. 2/13/2014 22 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Numerical Example 1 (of 2) Minimize Subject to WSCPPP Results Behaviors of different objective functions for a convex frontier

23. 2/13/2014 23 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Example 2 WSCPPPResults Behaviors of different objective functions for a concave frontier

24. 2/13/2014 24 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development The Reality of Uncertainty and Risk 1- Non-Deterministic Forum -- SDM 2- Traditional Factor-of-Safety approach is rapidly becoming an anachronistic relic of the past 3- Development of probabilistic design optimization methods 4- New MDO methods emerge to model risk and uncertainty 5- Profit as a design metric gains acceptance 6- Growing recognition that optimization in Conceptual Design is a necessity 7- TC has moves to Engineering & Technology Management Group to explore expanded collaboration

25. 2/13/2014 25 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Not Primarily a Technical Problem Critical Issues are: EDUCATION, MANAGEMENT, AND ORGANIZATION CULTURE A Challenge? INJECTING MDO INTO INDUSTRIAL PRACTICE:

26. 2/13/2014 26 Engineering & Technology Management Group Engineering Technology Management Tracking the Constant of Change Management History Society Legal Aspects LogisticsSupply Chain Systems Engineering Economics Risk Technical Information Multidiscipline Design Product Development Concluding Remarks The picture is somewhat muddied! Much of good news; yet much to be desired. MDOs power is evident. Yet its strongest influence can be felt in this decade if -- its application in a holistic setting comes to pass, and -- key methodological developments take place in collaboration with non-traditional participants MDO is a unifying indispensable glue, if we are to effectively design the ultra-safe, profitable, and effective design of the future For more information: www.rpi.edu/~messac