Lecture Notes 01

ME503
Advanced Design of Engineering Systems
Dr. Ruben E. Perez
Royal Military College of Canada

Course Information
Time & Location:
TBD (3 periods per week)
Pre-requisites:
Multivariable calculus & Linear Algebra
Familiarity with programming (C/C++, Fortran, Matlab,
Python)
Useful links for programming:

Python: Open source Interpreted Language
http://www.python.org
Octave: Open source Matlab clone
http://www.gnu.org/software/octave
C/C++: Open source C/C++ compiler
http://gcc.gnu.org
Fortran: Open source Fortran compiler
http://gcc.gnu.org/wiki/GFortran

c Dr. R. Perez, RMC ME503, Adv. Dsg. Eng. Sys. 2/787
Course Information
Reference
Nocedal and Wright, Numerical Optimization, Springer, 1999
Belegundu and Chandrupatla, Optimization Concepts and
Applications in Engineering, Prentice Hall, 1999
Rao, Engineering Optimization: Theory and Practice, John
Wiley & Sons, 1996
Onwubiko, Introduction to Engineering Design Optimization,
Prentice Hall, 2000
Chong and Zak, An Introduction to Optimization, John Wiley &
Sons, 2008
Fletcher, Practical Methods of Optimization, John Wiley &
Sons, 1991
Suh, The Principles of Design, Oxford University Press, 1990

Course Information
Marking Scheme
6 Assignments (10% each)
1 Sensitivity Analysis - Due Week 3
2 Line Search Methods - Due Week 5
3 Unconstrained Optimization - Due Week 7
4 Constrained Optimization - Due Week 9
5 Gradient-Free Optimization - Due Week 11
6 Multidisciplinary Design Optimization - Due Week 13
Course Project (40%) - Due Week 14 (Apr. 19)
Bear in mind:
You can discuss ideas with colleagues but you must program and solve the
problem sets on your own.
The solutions you submit must reect your understanding of the material.

Course Objectives
Develop the skills to formulate design optimization

problems based on its functional characteristics and
requirements
Develop an understanding for the numerical optimization
techniques used to solve such problems
Apply the above objectives in a practical engineering
project (can be related to your research)

Course Objectives

requirements
This course will give you both the analytical and numerical
skills to deal with complex engineering problems in an optimal
manner

Course Objectives

requirements
This course will give you both the analytical and numerical
skills to deal with complex engineering problems in an optimal
manner
But what is considered optimal?

Introduction & Background
What is Design?
Design may be formally dened as the creation of
synthesized solutions that satisfy perceived needs through
the mapping between the functional domain and the
physical domain, through the proper selection of design
alternatives that satisfy the prescribed functions. [1]
The design process is a map of how to get from an specic
object need to the nal product. [2]
In view of design modeling, design is a state of
conguration, say X = {xi }T ( i [1, n]), that intends to
satisfy the functional requirements prescribed for a
collection of design attributes.

What is Design?
Design may be formally dened as the creation of
synthesized solutions that satisfy perceived needs through
the mapping between the functional domain and the
physical domain, through the proper selection of design
alternatives that satisfy the prescribed functions. [1]
The design process is a map of how to get from an specic
object need to the nal product. [2]
In view of design modeling, design is a state of
conguration, say X = {xi }T ( i [1, n]), that intends to
satisfy the functional requirements prescribed for a
collection of design attributes.
Design is by nature a mapping process

Phases of Design
Customer Functional Physical Process
Domain Domain Domain Domain
Mapping Mapping Mapping

{CNs} {FRs} {DAs} {PCs}
Functional Design
Conceptual Design
Embodiment Design Detail Design
Design Domain Mappings [3]

Phases of Design
Functional design: focus on the function of the product

What must be the product good for? (determine set of
functional requirements)
What are the numerical or qualitative functional
requirements on its performance?
What are the undesired behaviours be prevented?
Conceptual design: nd a basic engineering structure that

can deliver the desired functions while avoiding undesired
characteristics as determined during functional design

Phases of Design
Embodiment design: nd a realizable structure consisting of

a number of sub-modules and components, and interfaces
between these
Detail design: incorporate the manufacturing issues into the

design to be used for production

Phases of Design and Design Modeling
F unctional
D esign F u n c tio n a l
R e q u ire m e n ts
D esign M odeling D om ain
F u n d a m e n ta l In te g ra te d D e ta il
C onceptual S y s te m E m bodim ent S y s te m D etail S y s te m
D esign D esign D esign
S e ts o f d e s ig n
v a ria b le s /a ttrib u te s
E ngineering
V alidation
Engineering validation: investigate the results of design

against the functional specications

Characteristics of Design Process
Uncertainty reduction process

How to treat uncertainties (from exibility to singularity)?
Decision making process

How to model design decisions?
Iterative control process

How to model design iterations (or re-design)?

What is Modeling?
A model is an abstraction of reality [4]
It helps to manipulate design computationally
Modeling is the process of arriving at a set of postulates,
data, and inferences that describe an entity or state of
aairs mathematically
In a broad sense, model refers to either a set of
mathematical equations and logic rules, and the solutions
to them

What is Modeling?
A model is an abstraction of reality [4]
It helps to manipulate design computationally
Modeling is the process of arriving at a set of postulates,
data, and inferences that describe an entity or state of
aairs mathematically
In a broad sense, model refers to either a set of
mathematical equations and logic rules, and the solutions
to them
-The necessity of design computing and usefulness of models

become one of the main driving force of this course
-The other one is how to solve numerically such design
modelling and nd the best designs

Why use Modelling in Design?
Engineering design tends to be large and complex (e.g.,

concurrent engineering)
The common, experience-based rules-of-thumb approach is
not useful for large-scale design
For analysis, physical design prototyping is expensive and
time-consuming
Accurate and precise computing based on design modeling
is essential to ensure the obtaining of a successful design

Challenges of Large-Scale Design
Dierent aspects need to be considered

Many designers / teams are involved, and they may be
located at dierent places. Communication becomes an
important issue here
Design decisions from dierent designers may aect each
other (often highly coupled)

The Need for Engineering Modeling
Engineering models can provide common language to help

the communication among designers
Models can help extract the important characteristics from
complex design (very useful in conceptual design)
Models can help predict eectively the relationship
between design decisions and performance

Types of Modeling in Engineering Design

Shape modeling
Abstraction of the artifacts shape, geometry and structure
such as geometric modeling, solid modeling and feature
modeling
Help to visualize the physical entities of the design,
especially the physical layout of the design
Function modeling
Abstraction of the design performance and behaviors
through simulation such as CFD and FEA
Help to predict the behaviors of the artifact and its
performance

Hierarchy of Major Functions in CAD

To support
Design Modelling decision
making
To reveal
Shape Modelling system Function Modelling
behaviour
Solid Geometric Feature

Simulation
Modelling Modelling Modelling
Shape Modelling: concerned with physical/geometrical reality

of the design
Function Modelling: concerned with the relational/behavioural
reality of the design

What is Design Modeling?
Viewed as high-level modeling above shape and function

modelling
Helps on the formalization of the design computing
process so as to support the generation of design
alternatives and the selection of a design


modelling
Design Modelling helps to obtain a desired system by specifying

design requirements and to improve its design through iterative
adjustments


modelling
Design Modelling helps to obtain a desired system by specifying

design requirements and to improve its design through iterative
adjustments
Automating the iterative adjustments towards the best possible
design becomes the other scope of this course: Optimization

Low-Level Modeling and Design Modeling
Design Modelling
Low-Level Modelling
Design Required System Design

Needs System Behaviour Adjustments
No Acceptable
Design
Yes

Low-Level Modeling
Simulation & analysis are typical tools used in low-level
modelling to aid designers in decisions making.
Simulation
Computer-based experiment to predict the
behavior of a system (only an approximate testing
of the real design).
Analysis
Treatment of design attributes (Whether the
design satises FRs, Whether the design violates
design availability) to adjust design components
for improvement
An understanding of underlying principles and physical rationale

are required by the models used in simulation & analysis.

Low-Level Modeling
Design Functions
(via simulation) Analysis
Design Design Good
Components Attributes Design?
Adjustment
Analysis

Outcome of Design Modelling

Before a design modelling process can be considered complete
two questions need to be answered:
Is the design adequate?
Can the design be improved?


Adequate Design
satises the design functional requirements while keeping
the undesirable characteristics within tolerable limits


Adequate Design
Optimal Design
best design among the set of alternatives that satises the
design functional requirements while keeping the
undesirable characteristics within tolerable limits


Adequate Design
Optimal Design
best design among the set of alternatives that satises the
design functional requirements while keeping the
undesirable characteristics within tolerable limits
But what is considered best (optimum)?

Benets of Design Modeling
Automate the design computing process

Govern the solution process towards a desired design as
the designer wishes
Enhance the accuracy of designing-in performance at lower
cost
Alternate the virtual models easily lower trial cost
Formalize and formulate dierent aspects of design
Help dierent designers to communicate with ease and
eciency

The Importance of Obtaining Optimal Designs

In industry, the need to reduce costs and improve eciency
requires making the best possible design decision.
70%
Influence % on Product Cost
Who Cast the Biggest

SHADOW?
20%
5%
5%
30%
Overhead
15%
Labor
50%
Materials
5%
Design
The Design Inuence

The Importance of Obtaining Optimal Designs
Sample Case: Aerospace industry where there is a large payo

from improving the design.
Main concern in aerospace: Cost!
Furthermore in aerospace: $ W
For Aircraft:
Dinduced
Wpayload L Wfuel W $
Sw Dfriction
For Spacecraft:
Wpayload Wfuel W $

Applications of Design Modelling & Optimization
Airfoil Design [5]

Lift-to-drag ratio maximization modifying airfoil shape and
angle of attack with limits on thickness and chord
64
0
62
-4 -1
Initial D es ign 60
-3
F inal D es ign -2
log(||G radient||)
58
Cp
-2
C l/C d
-3
-1 56
C l/C d
0 54 -4
G radient
1 52 -5
0 0.2 0.4 0.6 0.8 1
X /C
50
-6
10 20 30 40 50
F low S olves and G radient E valuations
M = 0.25, Re = 2.88 106
Lift-to-drag ratio improved by 10.3%

Airfoil Design [5]

Drag minimization with xed lift modifying airfoil shape and
angle of attack with limits on thickness and chord
0.024
R AE 2822
-1
0.022 F inal D es ign
-0.5
0.02
Cp
0
Cd
0.018
0.5
R AE 2822
F inal D es ign 0.016
1
0 0.25 0.5 0.75 1
X /C
0.014
0.65 0.7 0.75
Mach Number
M = 0.74, Baseline Airfoil: RAE2822, = 2.9
Drag reduced by 36.4%

Airfoil Design [5]

Drag minimization for xed lift with multiple ight conditions
modifying airfoil shape and angle of attack with limits on
thickness and chord
0.024
R AE 2822
-1
0.022 F inal D es ign
-0.5
0.02
Cp
Cd
0
0.018
0.5
R AE 2822
F inal D es ign 0.016
1
0 0.25 0.5 0.75 1
X /C 0.014
0.65 0.7 0.75
Mach Number
Four ight conditions: M1 = 0.68, M2 = 0.71, M3 = 0.74,
M4 = 0.76.

Airfoil Design [5]

Trade-o between Lift and Drag Coecients
L =0.99
L =0.99
0.012 C L =0.549
L =0.7 C D =0.0121
L =0.5
0.0115
L =0.3
L =0.2
0.011
L =0.1
CD
L =0.05
0.0105
L =0.01
L =0.01
C L =0.132
0.01 C D =0.0104
0.0095
-0.5 -0.4 -0.3 -0.2
-C L

Structural Topology Optimization [6]

Find the shape and topology of a structure that has the
minimum compliance (maximum stiness) for a given loading
condition.

Structural Topology Optimization [6]

Image Reconstruction [7, 8]
Minimize noise of polluted images
Original Contaminated Noise Cancellation

Image Image Optimized Image

Sailboat Optimization
Design shape of americas cup sailboat to maximize its
performance over dierent wind conditions.
Movie courtesy of Mr. Ryan Henderson

Low-Boom Supersonic Aircraft Design [9]

Reduce sonic boom strength on the ground by changing shape
and weight of the aircraft.
Gulfstream Aerospace conguration.

Cruise @ M = 1.8, 55,000 feet; Payload: 8-10 Passengers; Range:
5,000 nm; Weight: 100,000 lbs; L/D = 910; Swing-wing concept.

Pressure Signature Analysis


Two conicting goals: minimum drag and minimum boom
overpressure.

Optimization of Non-Planar Lifting Surfaces [10]
5
Z
50
0
40
0
30
10
20 Y
X 20
10
30
0
Aerodynamics: medium-delity potential ow solver

Structures: equivalent beam nite element model


Minimize Drag subject to geometric and aerodynamic
constraints
Drag reduced by 22% compared to conventional (planar) wing

of equivalent lift

Maximize range subject to geometric, aerodynamic, and

structural constraints
5
Z
0 60
0
5 40
10
Y
X 15
20
20
25
30 0
Higher range and L/D ratio as compared to planar-wing and

wing-winglet congurations


Maximize range subject to geometric, aerodynamic, and
structural constraints
10
X
15
20
25
30
0 20 40 60

Optimization of Non-Planar Lifting Surfaces
Boeing 767 Raked Wingtip Integration

Aero-Structural Design of a Supersonic Business Jet [11]

Minimize aircraft drag subject to aerodynamic and structural
considerations.
Flow Surface Geometry Structure
pressures Nodal forces
Mesh Nodal
displacements displacements
Natural laminar supersonic business jet, @ M = 1.8, 55,000 feet;

Range = 5,300nm
Aerodynamics: parallel, multiblock NavierStokes ow solver
Structures: nite element model with plates and trusses

Aero-Structural Design of a Supersonic Business Jet [11]
Baseline conguration and design variables

Aero-Structural Design Optimization [11]
Optimized design


Lecture Notes 01

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ME503

Advanced Design of Engineering Systems

Dr. Ruben E. Perez

Royal Military College of Canada

Useful links for programming:

Develop the skills to formulate design optimization

Develop the skills to formulate design optimization

Develop the skills to formulate design optimization

But what is considered optimal?

Design is by nature a mapping process

Mapping Mapping Mapping

Embodiment Design Detail Design

Design Domain Mappings [3]

Functional design: focus on the function of the product

Conceptual design: nd a basic engineering structure that

Embodiment design: nd a realizable structure consisting of

Detail design: incorporate the manufacturing issues into the

Phases of Design and Design Modeling

Engineering validation: investigate the results of design

Characteristics of Design Process

Uncertainty reduction process

Decision making process

Iterative control process

-The necessity of design computing and usefulness of models

Why use Modelling in Design?

Engineering design tends to be large and complex (e.g.,

Challenges of Large-Scale Design

Dierent aspects need to be considered

The Need for Engineering Modeling

Engineering models can provide common language to help

Types of Modeling in Engineering Design

Hierarchy of Major Functions in CAD

Solid Geometric Feature

Shape Modelling: concerned with physical/geometrical reality

What is Design Modeling?

Viewed as high-level modeling above shape and function

What is Design Modeling?

Viewed as high-level modeling above shape and function

Design Modelling helps to obtain a desired system by specifying

What is Design Modeling?

Viewed as high-level modeling above shape and function

Design Modelling helps to obtain a desired system by specifying

Low-Level Modeling and Design Modeling

Design Required System Design

An understanding of underlying principles and physical rationale

Outcome of Design Modelling

Outcome of Design Modelling

Outcome of Design Modelling

Outcome of Design Modelling

But what is considered best (optimum)?

Benets of Design Modeling

Automate the design computing process

The Importance of Obtaining Optimal Designs

Who Cast the Biggest

The Design Inuence

The Importance of Obtaining Optimal Designs

Sample Case: Aerospace industry where there is a large payo

Main concern in aerospace: Cost!

Airfoil Design [5]

M = 0.25, Re = 2.88 106

Lift-to-drag ratio improved by 10.3%

Airfoil Design [5]

Drag reduced by 36.4%

Airfoil Design [5]