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Multi-objective optimisation of ultrasonically welded dissimilar joints through machine learning

Author

Listed:
  • Patrick G. Mongan

    (Confirm Smart Manufacturing Research Centre
    University of Limerick)

  • Vedant Modi

    (University of Limerick)

  • John W. McLaughlin

    (University of Limerick)

  • Eoin P. Hinchy

    (Confirm Smart Manufacturing Research Centre
    University of Limerick)

  • Ronan M. O’Higgins

    (University of Limerick
    University of Limerick)

  • Noel P. O’Dowd

    (Confirm Smart Manufacturing Research Centre
    University of Limerick
    University of Limerick)

  • Conor T. McCarthy

    (Confirm Smart Manufacturing Research Centre
    University of Limerick
    University of Limerick)

Abstract

The use of composite materials is increasing in industry sectors such as renewable energy generation and storage, transport (including automotive, aerospace and agri-machinery) and construction. This is a result of the various advantages of composite materials over their monolithic counterparts, such as high strength-to-weight ratio, corrosion resistance, and superior fatigue performance. However, there is a lack of detailed knowledge in relation to fusion joining techniques for composite materials. In this work, ultrasonic welding is carried out on a carbon fibre/PEKK composite material bonded to carbon fibre/epoxy composite to investigate the influence of weld process parameters on the joint’s lap shear strength (LSS), the process repeatability, and the process induced defects. A 33 parametric study is carried out and a robust machine learning model is developed using a hybrid genetic algorithm–artificial neural network (GA–ANN) trained on the experimental data. Bayesian optimisation is employed to determine the most suitable GA–ANN hyperparameters and the resulting GA–ANN surrogate model is exploited to optimise the welding process, where the process performance metrics are LSS, repeatability and joint visual quality. The prediction for the optimal LSS was subsequently validated through a further set of experiments, which resulted in a prediction error of just 3%.

Suggested Citation

  • Patrick G. Mongan & Vedant Modi & John W. McLaughlin & Eoin P. Hinchy & Ronan M. O’Higgins & Noel P. O’Dowd & Conor T. McCarthy, 2022. "Multi-objective optimisation of ultrasonically welded dissimilar joints through machine learning," Journal of Intelligent Manufacturing, Springer, vol. 33(4), pages 1125-1138, April.
    • Handle: RePEc:spr:joinma:v:33:y:2022:i:4:d:10.1007_s10845-022-01911-6
    DOI: 10.1007/s10845-022-01911-6
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    References listed on IDEAS

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    1. Michael D. T. McDonnell & Daniel Arnaldo & Etienne Pelletier & James A. Grant-Jacob & Matthew Praeger & Dimitris Karnakis & Robert W. Eason & Ben Mills, 2021. "Machine learning for multi-dimensional optimisation and predictive visualisation of laser machining," Journal of Intelligent Manufacturing, Springer, vol. 32(5), pages 1471-1483, June.
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