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At least 289 records · Page 16

Simulation-driven design optimization of reaction injection molding (RIM) process for polydicyclopentadiene (pDCPD): Minimizing cycle time, defects, and warpage

Replacing metal components in trucks, trailers, and buses with lightweight polymer composites is challenging due to high temperatures and complex manufacturing. The Reaction Injection Molding (RIM) process using Dicyclopentadiene (DCPD) resin offers a solution by producing robust parts with excellent stiffness, impact strength, and resistance properties. Simulations are essential for optimizing this process, predicting defects, and improving quality. However, most commercial software is tailored for thermoplastics, requiring thermoset users to generate their own datasets. In this study, a material data card for DCPD was developed to perform RIM simulations. Design of Experiments (DOE) was used to identify key factors affecting filling, curing, and warpage, aiming to minimize cycle time and defects. The simulations explored varying injection gate parameters (size, location, number) and process conditions (mold/resin temperature, injection/curing pressure). Results showed that gate design significantly impacts filling behavior and defects. A single central gate provided balanced flow with fewer defects, while two corner gates led to more defects. Additionally, lower injection pressure increased filling time, while higher mold temperature accelerated curing but led to more warpage. In conclusion, this optimization framework aims to enhance DCPD part performance and promote sustainable manufacturing by reducing waste and energy consumption.

42 ENGINEERING↗

Transient Storage Model Parameter Optimization Using the Simulated Annealing Method

Hyporheic exchange in streams is critical to ecosystem functions such as nutrient cycling along river corridors, especially for slowly moving or small stream systems. The transient storage model (TSM) has been widely used for modeling of hyporheic exchange. TSM calibration, for hyporheic exchange, is typically used to estimate four parameters, including the mass exchange rate coefficient, the dispersion coefficient, stream cross-sectional area, and hyporheic zone cross-sectional area. Prior studies have raised concerns regarding the non-uniqueness of the inverse problem for the TSM, that is, the occurrence of different parameter vectors resulting in TSM solution that reproduces the observed in-stream tracer break through curve (BTC) with the same error. This leads to practical non-identifiability in determining the unknown parameter vector values even when global-optimal values exist, and the parameter optimization becomes practically non-unique. To address this problem, we applied the simulated annealing method to calibrate the TSM to BTCs, because it is less susceptible to local minima-induced non-identifiability. A hypothetical (or synthetic) tracer test data set with known parameters was developed to demonstrate the capability of the simulated annealing method to find the global minimum parameter vector, and it identified the “hypothetically-true” global minimum parameter vector even with input data that were modified with up to 10% noise without increasing the number of iterations required for convergence. The simulated annealing TSM was then calibrated using two in-stream tracer tests conducted in East Fork Poplar Creek, Tennessee. In conclusion, simulated annealing was determined to be appropriate for quantifying the TSM parameter vector because of its search capability for the global minimum parameter vector.

54 ENVIRONMENTAL SCIENCES↗

Exploring the Great Pyramid: Stand-Alone Monte Carlo Simulations for Detector Optimization

Cosmic-ray muon imaging has been used to non-destructively examine the Pyramids of Khufu and Khafre on the Giza Plateau; the EGP project will continue this line of research by undertaking a full tomographic scan of the former and, in doing so, will increase the sensitivity of the technique by upwards of two orders of magnitude. This paper details the development of stand-alone Monte Carlo simulations intended to aid in optimizing the EGP detector system. While the rectangular scintillator model considered here does provide sucient position resolution in a few specic test cases, it is not the optimal telescope design. An attempted detector modication to permit tagging of muons by their incident momenta is also discussed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Multiscale and multiphysics FEA simulation and materials optimization for laser ultrasound transducers

In this study, the relationship between the nanocomposite design and the laser ultrasound transducer (LUT) characteristics was investigated through simulations in multiple scale levels for material behavior, device response, and acoustic wave propagation in media. First, the effects of the nanoparticle size and concentration on the effective properties of composites were quantitatively investigated with the finite element analysis (FEA) method. Second, the effective properties of the nanocomposite were assigned to the layer, which is modeled as a homogeneous material, in the FEA for the LUT simulating the energy conversion from the incident laser to the acoustic wave. Finally, the ultrasound propagation in the water was calculated by a theoretical wave propagation model. The FEA-based prediction was compared with the experimental data in the literature and a theoretical analysis for LUT based on Thermal-Acoustic coupling. As a result, the ultrasound waves on the transducer surface and at a distance in the water could be predicted. Based on the hierarchically integrated prediction procedure, the optimal conditions of the photoacoustic nanocomposites were investigated through the parametric study with the particle size and concentration as variables. The results guide the material designs optimized for different device characteristics, such as high pressure and broad bandwidth.

36 MATERIALS SCIENCE↗

Designing Monte Carlo Simulation and an Optimal Machine Learning to Optimize and Model Space Missions

This paper investigates applying artificial intelligence (AI) algorithms to attitude control system of satellites to optimally tune the controller using high performance computing. This methodology is applied to the Virtual Telescope for X-ray Observation mission, which is a precise formation of two separate spacecraft observing multiple objects in the space in the X-ray domain. The mission is divided into phases based on the instrumentation and the mission goal. To reach an stable precise formation robust to stochastic slew and slew rate (i.e., Euler angles and angular velocities) in a minimal constrained time T , consumed energy of the attitude control system, denoted as E, and root-mean-square state error of attitude control system, denoted as e, are minimized. Monte-Carlo simulation is used for the sensitivity analysis of optimization and designing a controller. Deep neural networks (DNN), Gaussian processes (GP), and support vector regression (SVR) learn this optimization as a surrogate model, while their hyperparameters are optimized in a novel approach. THETA supercomputer at Argonne Leadership Computing Facility (ALCF) is used for optimizing the hyperparameters of DNN. The surrogate model meets the requirements of the mission, and it shows a better performance over the optimization and Monte-Carlo. The optimal DNN can satisfy the mission requirements e and T while reducing E for 90% compared to the other given methods.

42 ENGINEERING↗

Robust Multivariable Optimization and Performance Simulation for ASIC Design

Application-specific-integrated-circuit (ASIC) design for space applications involves multiple challenges of maximizing performance, minimizing power, and ensuring reliable operation in extreme environments. This is a complex multidimensional optimization problem, which must be solved early in the development cycle of a system due to the time required for testing and qualification severely limiting opportunities to modify and iterate. Manual design techniques, which generally involve simulation at one or a small number of corners with a very limited set of simultaneously variable parameters in order to make the problem tractable, are inefficient and not guaranteed to achieve the best possible results within the performance envelope defined by the process and environmental requirements. What is required is a means to automate design parameter variation, allow the designer to specify operational constraints and performance goals, and to analyze the results in a way that facilitates identifying the tradeoffs defining the performance envelope over the full set of process and environmental corner cases. The system developed by the Mixed Signal ASIC Group (MSAG) at the Goddard Space Flight Center is implemented as a framework of software modules, templates, and function libraries. It integrates CAD tools and a mathematical computing environment, and can be customized for new circuit designs with only a modest amount of effort as most common tasks are already encapsulated. Customization is required for simulation test benches to determine performance metrics and for cost function computation.

DuMonthier, Jeffrey↗

Model-Based Control of a Nonlinear Aircraft Engine Simulation using an Optimal Tuner Kalman Filter Approach

This paper covers the development of a model-based engine control (MBEC) methodology featuring a self tuning on-board model applied to an aircraft turbofan engine simulation. Here, the Commercial Modular Aero-Propulsion System Simulation 40,000 (CMAPSS40k) serves as the MBEC application engine. CMAPSS40k is capable of modeling realistic engine performance, allowing for a verification of the MBEC over a wide range of operating points. The on-board model is a piece-wise linear model derived from CMAPSS40k and updated using an optimal tuner Kalman Filter (OTKF) estimation routine, which enables the on-board model to self-tune to account for engine performance variations. The focus here is on developing a methodology for MBEC with direct control of estimated parameters of interest such as thrust and stall margins. Investigations using the MBEC to provide a stall margin limit for the controller protection logic are presented that could provide benefits over a simple acceleration schedule that is currently used in traditional engine control architectures.

Control Theory↗

Finite Difference Methods for Turbulence Simulations

The optimal finite difference discretization used in simulations of turbulent flows is influenced by both, the type of the scale resolving simulation (DNS or LES), as well as the flow-physics (hydrodynamic instabilities, shocks, acoustics, etc.) one expects to resolve. Insight into dispersion and dissipation error requirements for some common scale-resolving simulation scenarios help to highlight the issues faced in selecting a scheme.

Finite Difference Methods↗

Initial position optimization in molecular dynamics simulations for a Coulomb system

A new algorithm for molecular dynamics (MD) simulations is developed to optimize plasma particle distributions at given initial temperatures. By combining velocity scaling and reassignment, the method effectively eliminates the initial rise and oscillation in temperatures observed with randomly distributed positions. These rises and oscillations are undesired numerical artifacts observed in conventional plasma MD simulations, arising from unoptimized particle positions. The algorithm demonstrates temperature relaxation without initial rises or oscillations, as well as precise flow velocity relaxation, enabling accurate measurement of relaxation times. The code is accelerated using graphics processing units for parallel processing, enhancing the study of plasma dynamics. The proposed method for distributing physically valid particles in MD simulations enables accurate studies of intrinsic collision processes in plasmas, including the dynamics of strongly coupled plasmas, plasma–wave interactions, and transport phenomena in magnetized plasmas. The paper concludes with a discussion of potential applications and future enhancements to the algorithm.

Jo, Jawon (ORCID:0009000924193285)↗

An Optimization Platform Based on Coupled Indoor Environment and HVAC Simulation and its Application in Optimal Thermostat Placement

Model-based optimization can help improve the indoor thermal comfort and energy efficiency of Heating, Ventilation and Air Conditioning (HVAC) systems. The models used in previous optimization studies either omit the dynamic interaction between indoor airflow and HVAC or are too slow for model-based optimization. To address this limitation, we propose an optimization methodology using coupled simulation of the airflow and HVAC that captures the dynamics of both systems. We implement an optimization platform using the coupled models of a coarse grid Fast Fluid Dynamics model for indoor airflow and Modelica models for HVAC which is linked to the GenOpt optimization engine. Then, we demonstrate the new optimization platform by studying the optimal thermostat placement in a typical office room with a VAV terminal box in the design phase. After validating the model, we perform an optimization study, in which the VAV terminal box is dynamically controlled, and find that our optimization platform can determine the optimal location of thermostat to achieve either best thermal comfort or least energy consumption, or the combined. Finally, the time cost for performing such optimization study is about 6.2 h, which is acceptable in the design phase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Parallel derivative-free optimization for simulation-based design of behind-the-meter energy systems

In this work, the integrated design and dispatch of behind-the-meter or distributed resources (e.g. stationary battery storage and solar PV generation) is considered. A simulation-based framework is employed, generating high-fidelity results with closed-loop predictive control at a fine resolution, at the expense of high computational cost (several minutes to a few hours per design point). To address this challenge, parallel derivative-free design methods are considered. Four methods are compared, including state-of-the-art surrogate-based methods (Radial-Basis Functions and Gaussian processes) and sampling strategies, an evolutionary-based method, and a simple sequential grid refinement method. As a case study, two types of design problem with increasing complexity are considered, namely, the design of behind-the-meter resources (three design variables) and the inclusion of grid capacity (four design variables). The second yields a constrained design problem for which violations can only be determined after solving the computationally expensive simulation. For the three-dimensional case, all methods present a good performance, achieving a solution within 1% of the optimum after the first iteration, with the sequential grid refinement exhibiting the fastest convergence and achieving the best final objective value. This indicates that the parallel evaluation of multiple sampling points may be more important than the choice of method for small decision spaces. For the four-dimensional constrained case, the Genetic Algorithm presents the best tradeoff between performance and computational effort, while the rough objective function terrain generated by constraint violation penalties reduces the performance of surrogate-based methods. Contour plots with flat regions indicate flexibility in the optimal design and highlight the importance of characterizing the solution space.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Computational simulations and beamline optimizations for an electron beam degrader at CEBAF

An electron beam degrader is under development with the objective of measuring the transverse and longitudinal acceptance of the Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab. This project is in support of the CE+BAF positron capability. Computational simulations of beam-target interactions and particle tracking were performed integrating the GEANT4 and Elegant toolkits. A solenoid was added to the setup to control the beam's divergence. Parameter optimization of the solenoid field and magnetic quadrupoles gradient was also performed to further reduce particle loss through the rest of the injector beamline.

Lizárraga-Rubio, V.↗

Computer-Simulation Surrogates for Optimization: Application to Trapezoidal Ducts and Axisymmetric Bodies

Engineering design and optimization efforts using computational systems rapidly become resource intensive. The goal of the surrogate-based approach is to perform a complete optimization with limited resources. In this paper we present a Bayesian-validated approach that informs the designer as to how well the surrogate performs; in particular, our surrogate framework provides precise (albeit probabilistic) bounds on the errors incurred in the surrogate-for-simulation substitution. The theory and algorithms of our computer{simulation surrogate framework are first described. The utility of the framework is then demonstrated through two illustrative examples: maximization of the flowrate of fully developed ow in trapezoidal ducts; and design of an axisymmetric body that achieves a target Stokes drag.

Otto, John C.↗

Optimal placement of excitations and sensors by simulated annealing

The optimal placement of discrete actuators and sensors is posed as a combinatorial optimization problem. Two examples for truss structures were used for illustration; the first dealt with the optimal placement of passive dampers along existing truss members, and the second dealt with the optimal placement of a combination of a set of actuators and a set of sensors. Except for the simplest problems, an exact solution by enumeration involves a very large number of function evaluations, and is therefore computationally intractable. By contrast, the simulated annealing heuristic involves far fewer evaluations and is best suited for the class of problems considered. As an optimization tool, the effectiveness of the algorithm is enhanced by introducing a number of rules that incorporate knowledge about the physical behavior of the problem. Some of the suggested rules are necessarily problem dependent.

Salama, Moktar↗

Co-Simulation Model for Optimal Wind-Hydro Coordination Using Wind Farm Control Dynamics

The growing share of Variable Renewable Energy sources (VRES) in power systems presents challenges for regula- tors, grid operators and energy producers. The VRES’ operation has limited flexibility in their operations, as they are highly dependent on ambient environments. To address these challenges, decision-makers must consider multiple objectives, among these are revenue, power system services and mechanical load on wind turbines. Coordinated operation of power plants and different wind farm control strategies are examples of measures that can benefit these objectives. This study proposes a Multi-Objective Linear Programming (MOLP) model to simulate the optimum operation of wind and hydropower plants that share limited transmission capacity. Further, wind farm control dynamics are included to obtain realistic output power and accumulated damage. From this, a case study based on a relevant location in Norway is presented to analyze the improved effect of wind- hydro coordination and wind farm control in achieving the objectives of accumulated wind turbine damage and total revenue of the hybrid power system. In addition, the study considers the potential advantages of adding a variable-speed pump to the hydropower plant. The results demonstrate that by considering multiple objectives in the optimization, one may achieve better overall performance of the objectives. By utilizing the flexibility of hydro storage, the decision maker may adjust to obtain the most desired outcome. Moreover, the added flexibility of utilizing a pump for hydro storage shows great improvements for the combined revenue of the power plants and reduced curtailment of the wind farm. However, less impact is observed from using a variable speed pump compared to a fixed speed pump.

13 HYDRO ENERGY↗

Scalable Truck Charging Demand Simulation for Cost-Optimized Infrastructure Planning

This project developed a scalable, high-resolution model to simulate medium- and heavy-duty (MHD) electric truck charging demand and assess its impact on grid infrastructure. Using generative modeling, simulation, and cost optimization, the project delivered an end-to-end software pipeline and a library of 96 real-world scenarios for the Dallas–Houston megaregion. We demonstrated a modular architecture for transportation and grid modeling, implemented cost-optimized infrastructure planning methods, and quantified grid capital, operational, and environmental costs across a wide range of truck electrification scenarios. The results have been adopted by major utility stakeholders and contributed to regional planning efforts.

24 POWER TRANSMISSION AND DISTRIBUTION↗