Optimization in

Engineering Design
SECTION 1: INTRODUCTION

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Introduction
Extensively used in those engineering design problems where the emphasis is on
maximizing or minimizing a certain goal

Optimization in Engineering Design

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Introduction
➢These tasks involve either minimization or maximization (collectively known as
optimization) of an objective

Optimization in Engineering Design

➢Every designer should know a few aspects of the formulation procedure which
would help him or her to choose a proper optimization algorithm for the
chosen optimal design problem
➢Knowledge about the working principles of different optimization methods

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Course Outline
➢ Optimisation is generally referred to as finding the best solution to an
optimisation problem

Optimization in Engineering Design

➢ In engineering design activities, the design objective could be simply to
minimize the cost of production or to maximize the efficiency of production
➢ Optimisation methods can be broadly classified into two categories:
deterministic methods and stochastic methods.

Optimization

Deterministic Stochastic

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Course Outline
➢Optimal design process is the formulation of the design problem in a
mathematical format which is acceptable to an optimization algorithm

Optimization in Engineering Design

➢Optimization problems usually contain multiple design variables, but will start
with single-variable function optimization algorithms
➢a number of algorithms for optimizing unconstrained objective functions having
multiple variables
➢Number of algorithms for solving constrained optimization problems
➢Genetic algorithms—search and optimization
➢Algorithms that mimic natural evolution and genetics—are potential
➢Optimization algorithms and have been applied to many engineering design
problems

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 Industrial Design Optimization
➢Industrial design activities, a naive optimal design is
achieved by comparing a few (limited up to ten or so)

Optimization in Engineering Design

alternative design solutions created by using a priori problem
knowledge
➢An estimate of the underlying objective (cost, profit, etc.) of
each design solution is computed and the best design
solution is adopted
➢Achieving a quality product or of achieving a competing
product is never guaranteed to be fulfilled with the above
naive method
➢Optimization algorithms described in the course provide
systematic and efficient ways of creating and comparing new
design solutions in order to achieve an optimal design
➢It is usually time-consuming and computationally expensive

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 Optimal Problem Formulation

Optimization in Engineering Design

➢Impossible to apply a single formulation procedure for all engineering design
problems
➢Objective in a design problem and the associated design parameters vary from
product to product, different techniques need to be used in different problems
➢Purpose of the formulation procedure is to create a mathematical model of the
optimal design problem, which then can be solved using an optimization algorithm
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Flowchart: Optimal Design Procedure

Optimization in Engineering Design

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 Design Variables
➢Formulation of an optimization problem begins with identifying the
underlying design variables, which are primarily varied during the

Optimization in Engineering Design

optimization process
➢Design problem usually involves many design parameters, of which
some are highly sensitive to the proper working of the design
➢Important to understand that the efficiency and speed of optimization
algorithms depend, to a large extent, on the number of chosen design
variables
➢By selectively choosing the design variables, the efficacy of the
optimization process can be increased
➢First thumb rule of the formulation of an optimization problem is to
choose as few design variables as possible

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Constraints
➢Constraints represents some functional relationships among the design
variables and other design parameters

Optimization in Engineering Design

➢Mechanical & Civil engineering problems, the constraints are formulated to
satisfy the stress and deflection limitations
➢Nature & number of constraints to be included in the formulation depends on
the user

Eg. σ(𝑥) ≤
Inequality
𝑆𝑎𝑙𝑙𝑜𝑤
Types
Equality 𝛿(𝑥) = 5

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Objective Function
➢Find the objective function in terms of the design variables and other problem
parameters

Optimization in Engineering Design

➢Common engineering objectives involve minimization of overall cost of
manufacturing, or minimization of overall weight of a component, or
maximization of net profit earned, or maximization total life of a product, or
others

Eg. Profit,
Maximize
Comfort etc.
Objective
Function
Eg. Cost, stress,
Minimize
vibration

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Duality Principle
Can we use the

Optimization in Engineering Design

same algorithm to
be used for
minimization or
maximization???

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Variable Bounds
➢Final task of the formulation procedure is to set the minimum and the
maximum bounds on each design variable

Optimization in Engineering Design

➢Some problems require this information in order to confine the search
algorithm within these bounds

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Optimization Problem

Optimization in Engineering Design

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Formulation of Optimization Problem: Eg 1
Design a cylindrical can
• Can is completely enclosed and cost of material should be

Optimization in Engineering Design

minimum
• Can need to be stored on a shelf and dimensions of shelf
are such that radius of can should not exceed Rmax

Mathematical
Objective Optimisation
Formulation

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Formulation of Optimization Problem: Eg 1

Optimization in Engineering Design

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Formulation of Optimization Problem: Eg 1

Optimization in Engineering Design

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Formulation of Optimization Problem: Eg 1

Optimization in Engineering Design

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Formulation of Optimization Problem: Eg 2
Design

Optimization in Engineering Design

Variables???

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Selection of Design Variables
Constant Design
Design Variables

Optimization in Engineering Design

Parameters
Front coil stiffness, kfs ms=1000 kg, mfu=70 kg, mru=150 kg

Rear Coil stiffness, krs kft=20kg/mm, krt=20kg/mm

Front damper coefficient, αf J=550 kg-m2

Rear damper coefficient, αr l1=l2=1.6m, l=3.2 m

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Objective Function & Constraints
Objective Function can be defined as
𝐦𝐚𝐱 𝒂𝒃𝒔 𝒒𝟐 𝒕

Optimization in Engineering Design

𝑴𝒊𝒏𝒊𝒎𝒊𝒛𝒆
𝑨
Subject to,
𝟏𝟖 − 𝐦𝐚𝐱 𝒒′′′
𝟐 (𝒕) ≥ 𝟎
𝟎 ≤ 𝒌𝒇𝒔 , 𝒌𝒓𝒔 ≤ 𝟐
𝟎 ≤ 𝜶𝒇 , 𝜶𝒓 ≤ 𝟑𝟎𝟎

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 Optimization Algorithms: Classification
No. of Type of
No. of Nature of

Optimization in Engineering Design

Design Constraints Objective
Problem
Methodology
Objectives function
variables

Single Single Unconstrained Minimization Linear Traditional

Non
Multi Multi Constrained Maximization Non Linear
Traditional

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Traditional Optimization Methods
Single Multi variable
Multi variable

Optimization in Engineering Design

Variable constrained
A. Direct Search
A. Direct Search
1. Exhaustive search
1. Simplex search
2. Boundary phase 1. Penalty function
2. Hooke Jeeves Pattern
3. Interval halving 2. Method of multipliers
3. Powell’s Conjugate Direction
4. Fibonacci search 3. Variable Elimination
4. Complex search
B. Gradient Based 5. Random search
B. Gradient Based
1. Newton Raphson 6. Frank-Wolfe
1. Cauchy’s steepest descent
2. Bisection 7. Cutting Plane
2. Newton’s method
3. Secant
3. Marquardt method
4. Cubic Search

Unconstrained
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Non-Traditional Method
Swarm Other Nature
Evolutionary

Optimization in Engineering Design

Intelligence Inspired
1. Genetic 1. Particle Swarm 1. Simulated
Algorithm Optimization Annealing
2. Genetic 2. Artificial Bee 2. Cross Entropy
Programming Colony
3. Cuckoo Search
3. Evolutionary 3. Ant Colony
Programming Optimization 4. Grenade
Explosion Method
4. Differential 4. Fire fly
Evolution algorithm

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