Computational Simulation and Machine Learning for Quality Improvement in Composites Assembly

In applications spanning across aerospace, marine, automotive, energy, and space travel domains, composite materials have become ubiquitous because of their superior stiffness-to-weight ratios as well as corrosion and fatigue resistance. However, from a manufacturing perspective, these advanced materials have introduced new challenges that demand the development of new tools. Due to the complex anisotropic and nonlinear material properties, composite materials are more difficult to model than conventional materials such as metals and plastics. Furthermore, there exist ultra-high precision requirements in safety critical applications that are yet to be reliably met in production. Towards developing new tools addressing these challenges, this dissertation aims to (i) build high-fidelity numerical simulations of composite assembly processes, (ii) bridge these simulations to machine learning tools, and (iii) apply data-driven solutions to process control problems while identifying and overcoming their shortcomings. This is accomplished in case studies that model the fixturing, shape control, and fastening of composite fuselage components. Therein, simulation environments are created that interact with novel implementations of modified proximal policy optimization, based on a newly developed reinforcement learning algorithm. The resulting reinforcement learning agents are able to successfully address the underlying optimization problems that underpin the process and quality requirements.

Name thesis:degree_name

Doctor of Philosophy

Level thesis:degree_level

doctoral

Discipline thesis:degree_discipline

Industrial and Systems Engineering

Department dc:contributor.department

Industrial and Systems Engineering

Grantor dc:publisher

Virginia Tech

Year dc:date.issued

2023

Author dc:creator

• Lutz, Oliver Tim

Chair dc:contributor.committeechair

• Yue, Xiaowei

Committee members dc:contributor.committeemember

• Kong, Zhenyu
• Camelio, Jaime A.
• Bansal, Manish

• Reinforcement Learning
• Digital Twin
• Extreme Value Theory
• Finite Element Analysis
• Smart Manufacturing
• Composites Assembly

Statement dc:rights

• Creative Commons Attribution-NonCommercial 4.0 International

Licence dc:rights.uri

• http://creativecommons.org/licenses/by-nc/4.0/

Language dc:language.iso

en

Dc Identifier Other

vt_gsexam:38269

OAI identifier oai:identifier

oai:vtechworks.lib.vt.edu:10919/116083