Applications of Computational

Intelligence Techniques in
Engineering

B Samanta
International Visiting Professor
Robert Morris University

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Presentation Summary
 Motivation
 Computational Intelligence
 Different CI techniques
 Applications of CI techniques
 Recent Work
 Work done at RMU
 Way forward
 Conclusions
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Motivation
 Use of computers for better understanding and
interpretation of process/system behavior
 Use of available information to obtain input-output
mapping.
 Utilization of expert/operator knowledge
 Ability to use imprecise, uncertain information
 Integration of knowledge over multiple disciplines
 Automated machine learning inspired from nature
(neuroscience, genetics, behavioral science)
 Development of models for optimizing the system
performance satisfying the inherent system/process
constraints.

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Computational Intelligence
(CI)
 Intelligence built in computer programs
 Covers
 Evolutionary computing
 Fuzzy computing
 Neuro-computing
 Also known as
 Soft computing

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CI Techniques
 Artificial Intelligence (AI)
 Artificial Neural Networks (ANNs)
 Fuzzy Logic (FL)
 Support Vector Machines (SVM)
 Self Organizing Maps (SOM)- unsupervised
 Genetic Algorithm (GA)
 Genetic Programming (GP)
 Swarm Intelligence/Particle Swarm
Optimization (PSO)

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CI Techniques (contd.)
 ANNs
 Multi-layer Perceptron (MLP)
 Radial Basis Function (RBF)
 Probabilistic Neural Network (PNN)
 Fuzzy Logic + ANN
 Adaptive neuro-fuzzy inference system
(ANFIS)

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CI Techniques (contd.)
ANN structure
 Input layer

 Hidden Layer (s)

 Output layer

 Number of nodes in each layer

 Functions and their parameters

Mostly decided on trial and error basis

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ANN- a typical example
Input layer Hidden layer
x1 u1 y1

u2 y2
x2

. .
. . .
u.
Q
xN yM

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Fuzzy Logic
Steps involved
 Fuzzification using membership

functions (MFs)-input
 Generation of rule base

 Aggregation

 Defuzzification using MFs -output

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Fuzzy Logic (contd.)
 Input and output MFs
 Number
 Type
 Parameters
 Rule base (experience guided)

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Neuro-Fuzzy System
 Combines the advantages of fuzzy logic
(FL) and ANNs
 Starts with an initial FL structure
 Uses ANN for adapting the FL (MF)
parameters and the rule base to the
training data

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 Fuzzy Logic – An Example

ANFIS structure for an example system with 2 inputs and 1 output.

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Snapshot of rule base for an example system with 2 inputs and 1 output.

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Genetic Algorithms
 Construction of genome (individual)
 Generation of initial population (group of individuals)
 Evaluation of individuals
 Selection of individuals based on criteria
 Generation of new individuals
 Mutation
 Crossover
 Repetition of the process - generation, evaluation,
selection
 Termination of the process based on max generation
no. and/or performance criteria

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Combinations
 Combine advantages of GA and other classifiers
 GA and ANN
 GA and ANFIS
 GA and SVM
 for automatic selection of classifier structure and parameters
 ANNs -Number of neurons in hidden layer
 ANFIS - Number of MFs and their parameters
 SVM – SVM parameters
 Selection of most important system features from a pool
 Selection of most important sensors (in the context of on-line
condition monitoring and diagnostics)- sensor fusion.

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 Rotating Machine with Sensors

Signal Conditioning and Data Acquisition

Feature Extraction

Training Data Set Test Data Set

GA based selection of features and

parameters

Training of ANN/ SVM

No No
Is ANN/ SVM
Training
Complete ?
Yes

Is GA based
selection
over?
Yes

Trained ANN/ SVM with selected features

ANN / SVM Output

Machine Condition Diagnosis

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Fig. 1. Flow chart of diagnostic procedure
Genetic Programming (GP)
 GP – a branch of GA with a lot of similarities.
 Main difference of GP and GA is in the
representation of the solution.
 In GA, the output is in form of a string of
numbers representing the solution.
 GP produces a computer program in form of a
tree-based structure relating
 the inputs (leaves)
 the mathematical functions (nodes) and
 the output (root node).

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 GP output –An Example
 Terminals (leaves): inputs x1, x2 and constant 3
 Nodes: Math functions *,+, exp
 Output: x1*x2+exp(3)

(+ (* (X1 X2))(exp(3))

plus

exp
times

X1
X2
3
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Applications
 Computer Science
 Pattern Recognition (PR)
 Data Mining
 Knowledge Discovery/ Machine Learning
 Feature Extraction and Selection
 Mechanical Systems
 Condition monitoring and diagnostics
 Multiobjective optimization in design
 Control System Design
 Manufacturing Systems
 Development of data-driven models
 Multiobjective optimization of machining parameters

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Applications (contd.)
 Engineering Management/IE
 Inventory management
 Project selection
 Facility layout design
 Scheduling
 Medicine
 Patient condition monitoring and diagnosis
 Social Science
 Business
 Market analysis and forecasting
 Credit rating

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Recent Work
 Machine Condition Monitoring and Diagnostics
using
 ANNs-MLP, RBF, PNN
 SVM
 ANFIS
 GA-ANN
 GA-ANFIS
 GA-SVM
 GP
 Involving signal processing, feature
extraction, selection and sensor fusion
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Recent work (contd.)
 Materials
 ANN based estimation of fatigue life
 Modeling of material properties in terms of
heat treatment parameters
 Rotordynamics
 Control System Design

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Work done at RMU
 Intelligent Manufacturing Systems
 Development of Tool Wear Model
 ANFIS and GA-ANFIS
 Genetic Programming (GP)
 Development of machined surface roughness model
 ANFIS and GA
 Genetic Programming (GP)
 Mutliobjective optimization of machining parameters
 Minimization of machining cost
 Minimization of surface roughness
 Minimization of production time
 Subject to constraints on
 Operating parameters –speed, feed, depth of cut
 Cutting Force
 Power consumption
 Tested on 5 different data sets
 Involves different machining operations
 Milling,
 turning and
 Turning of hard material (>Rc 65)

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Tool Wear Model
 Mapping of Inputs and Outputs
 Inputs
 Tool type- geometry, material
 Work piece
 Cutting speed (V)
 Feed rate (f)
 Depth of cut (d)
 Vibration (Vx, Vy, Vz)
 Forces (Fx, Fy, Fz)
 Cutting Time (t)
 Outputs
 Tool wear
 Remaining Tool Life
 GA/GP based selection of characteristic inputs

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ANFIS based Tool Wear Model
– An Example
 Input pool
 Spindle speed (x1)
 Feed rate (x2)
 Machining time (x3)
 Ratio of forces in 2 directions: Fx (feed)/ Fz (tangential) (x4)

 Output – Tool wear level

 Data set
 Training – 25
 Test - 38
 Number of MFs - 2
 Performance –
 Training Root Mean Square Error (RMSE) 1.30%
 Test data set RMSE : 8.52%
 Training time 0.34 s

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 Fig. 1. Results of training data set
0.9
Actual
0.8 Predicted
Prediction error

0.7

0.6
Normalized Tool Life

0.5

0.4

0.3

0.2

0.1

-0.1
0 5 10 15 20 25
index i

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 Fig. 2. Results of test data set
1.2
Actual
Predicted
1 Prediction error

0.8

0.6
Normalized Tool Life

0.4

0.2

-0.2

-0.4
0 5 10 15 20 25 30 35 40
index i

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GA-ANFIS based roughness
model – An Example
 Input pool
 Spindle speed (x1)
 Feed rate (x2)
 Depth of cut (x3)
 Vibration in 3 directions
 x (radial) (x4)
 y (tangential) (x5)
 z (feed) (x6)
 Output – surface roughness
 Data set
 Training – 36
 Test - 24
 GA based selection of best 3 features: x2, x1, x5
 Number of optimum MFs - 2
 Performance –
 Training Root Mean Square Error (RMSE) 2.60%
 Test data set RMSE : 6.65%
 Training time 263.2 s

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Acrobat Document

RMU_Summer2005_Samanta 29
 Fig. 1. Results of training data set
0.9

Actual
0.8 Predicted
Prediction error

0.7

0.6
Normalized tool flank wear

0.5

0.4

0.3

0.2

0.1

-0.1
0 5 10 15 20 25 30 35 40
index i

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 Fig. 2. Results of test data set
1.2
Actual
Predicted
Prediction error
1

0.8
Normalized tool flank wear

0.6

0.4

0.2

-0.2
0 5 10 15 20 25
index i

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GP model for surface
roughness
 GP was used for same data sets
 Training – 36
 Test set – 24
 Performance
 Training RMSE: 3.79%
 Test RMSE : 6.90%
 Training time: 463.7 s

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GP output tree for Roughness model

power

sqrt
X2
exp

power

sqrt
X2
exp

power
asin
avg tanh power
X3
log10 log avg

divide acos tanh

X3
power log10
X4 X2
power plus divide

plus asin power

X2 X4 X3
asin step plus
X1 X2
step asin
X3 X4
step
X2

X3

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Publications Planned
 Predictive modeling of tool wear in turning
using adaptive neuro-fuzzy inference system
 Modeling and prediction of tool wear in
turning using genetic programming
 Predictive modeling of surface roughness in
turning using adaptive neuro-fuzzy inference
system and genetic algorithms

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Publications Planned (contd.)
 Modeling and prediction of surface roughness
in turning using genetic programming
 Predictive modeling of surface roughness in
milling using adaptive neuro-fuzzy inference
system and genetic algorithms
 Multiobjective evolutionary optimization of a
machining process

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Conferences/Journals
 North American Manufacturing Research Conference
(NAMRC 34 ), NAMRI/SME, May 23-26, 2006,
Milawukee, WI, USA.
 Flexible Automation and Intelligent Manufacturing
(FAIM) June 26-28, 2006, Univ of Limerick, Ireland.
 IFAC Symposium on Information Control in
Manufacturing (INCOM) May17-19, 2006, France.
 Journal of Manufacturing Systems/SME
 International Journal of Machine Tools & Manufacture

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Industry-RMU collaboration
Potential
 Interest in RMU-EOC research collaboration in
the area of Laser machining.
 Development of machining models using CI
 Multiobjective constrained optimization of
machining/laser system parameters
 Sensor fusion
 Interest in RMU-ExOne research collaboration
in the areas of 3D printing
 process
 system
 Design optimization

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Way Forward
 Scope for further collaboration with
RMU
 Teaching – Development of new elective or
short courses in consultation with Faculty
 Research – Joint supervision of projects/theses
at Senior, MS and PhD levels
 Collaborative work with Faculty
 Outreach- Industry and Government supported
research projects/contracts

RMU_Summer2005_Samanta 38
Conclusions
Increasing popularity of CI techniques
 Integrating capability over multiple disciplines

 Capability of incorporating imprecision and

uncertainty
 Suitability for hard-to-model processes

/systems
 Better alternatives to traditional hard

computing scenario

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THANKS
Thanks to
 RMU Administration

 Sponsor of the Program

 SEMS/Engineering Faculty, Staff

for the support and facilitating the visit

Thanks to you all (in audience)
 For your time and patience

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