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

Patrick G. Mongan (), Vedant Modi, John W. McLaughlin, Eoin P. Hinchy, Ronan M. O’Higgins, Noel P. O’Dowd and Conor T. McCarthy
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Patrick G. Mongan: Confirm Smart Manufacturing Research Centre
Vedant Modi: University of Limerick
John W. McLaughlin: University of Limerick
Eoin P. Hinchy: Confirm Smart Manufacturing Research Centre
Ronan M. O’Higgins: University of Limerick
Noel P. O’Dowd: Confirm Smart Manufacturing Research Centre
Conor T. McCarthy: Confirm Smart Manufacturing Research Centre

Journal of Intelligent Manufacturing, 2022, vol. 33, issue 4, No 15, 1125-1138

Abstract: 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%.

Keywords: Machine learning; Artificial neural network; Genetic algorithm; Bayesian optimisation; Ultrasonic welding; Dissimilar materials (search for similar items in EconPapers)
Date: 2022
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DOI: 10.1007/s10845-022-01911-6

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