arXiv subjects

Madhura Limaye

Publications and source records attributed to Madhura Limaye.

5 recordsLinked to original sources

arXiv2026

Probabilistic Predictions of Process-Induced Deformation in Carbon/Epoxy Composites Using a Deep Operator Network

Fiber reinforcement and polymer matrix respond differently to manufacturing conditions due to mismatch in coefficient of thermal expansion and matrix shrinkage during curing of thermosets. These heterogeneities generate residual stresses over multiple length scales, whose partial release leads to process-induced deformation (PID), requiring accurate prediction and mitigation via optimized non-isothermal cure cycles. This study considers a unidirectional AS4 carbon fiber/amine bi-functional epoxy prepreg and models PID using a two-mechanism framework that accounts for thermal expansion/shrinkage and cure shrinkage. The model is validated against manufacturing trials to identify initial and boundary conditions, then used to generate PID responses for a diverse set of non-isothermal cure cycles (time-temperature profiles). Building on this physics-based foundation, we develop a data-driven surrogate based on Deep Operator Networks (DeepONets). A DeepONet is trained on a dataset combining high-fidelity simulations with targeted experimental measurements of PID. We extend this to a Feature-wise Linear Modulation (FiLM) DeepONet, where branch-network features are modulated by external parameters, including the initial degree of cure, enabling prediction of time histories of degree of cure, viscosity, and deformation. Because experimental data are available only at limited time instances (for example, final deformation), we use transfer learning: simulation-trained trunk and branch networks are fixed and only the final layer is updated using measured final deformation. Finally, we augment the framework with Ensemble Kalman Inversion (EKI) to quantify uncertainty under experimental conditions and to support optimization of cure schedules for reduced PID in composites.

cs.CE↗

arXiv2026

A Decision Analysis Framework for High-fidelity and Low-fidelity Systems with Applications in Manufacturing Processes

Optimizing complex manufacturing processes often involves a trade-off between data accuracy and acquisition cost. High-fidelity data are accurate but limited, while low-fidelity data are abundant but often biased. Balancing these two sources is critical for efficient manufacturing optimization. To address this challenge, we develop a decision analysis framework based on multi-fidelity Gaussian process (GP) modeling based on the Kennedy-O'Hagan (KOH) framework. We propose a systematic Bayesian calibration approach using multi-fidelity GPs that explicitly quantifies the model discrepancy, and an algorithm that combines posterior sampling of calibration parameters with predictive sampling to characterize the distribution of optimal input settings and their associated uncertainty. These components are integrated into a five-stage practical workflow for the optimization of manufacturing processes. Through an illustrative example and two real-world applications in composite cure cycle optimization and injection molding process control, we demonstrate how the framework integrates information from both high-fidelity and low-fidelity data sources to support decision-making under parameter uncertainty.

stat.ME↗

arXiv2025

Uncertainty Estimation of the Optimal Decision with Application to Cure Process Optimization

Decision-making in manufacturing often involves optimizing key process parameters using data collected from simulation experiments. Gaussian processes are widely used to surrogate the underlying system and guide optimization. Uncertainty often inherent in the decisions given by the surrogate model due to limited data and model assumptions. This paper proposes a surrogate model-based framework for estimating the uncertainty of optimal decisions and analyzing its sensitivity with respect to the objective function. The proposed approach is applied to the composite cure process simulation in manufacturing.

stat.AP↗

arXiv2025

Numerical Simulation Informed Rapid Cure Process Optimization of Composite Structures using Constrained Bayesian Optimization

The present study aimed to solve the cure optimization problem of laminated composites through a statistical approach. The approach consisted of using constrained Bayesian Optimization (cBO) along with a Gaussian process model as a surrogate to rapidly solve the cure optimization problem. The approach was implemented to two case studies including the cure of a simpler flat rectangular laminate and a more complex L-shaped laminate. The cure optimization problem with the objective to minimize cure induced distortion was defined for both case studies. The former case study was two-variable that is used two cure cycle parameters as design variables and was constrained to achieve full cure, while the latter was four-variable and had to satisfy constraints of full cure as well as other cure cycle parameters. The performance of cBO for both case studies was compared to the traditional optimization approach based on Genetic Algorithm (GA). The comparison of results from GA and cBO including deformation and final degree of cure showed significant agreement (error < 4%). The computational efficiency of cBO was calculated by comparing the convergence steps for GA (>1000) and cBO (<50). The computational efficiency of cBO for all optimization cases was found to be > 96%. The case studies conclude that cBO is promising in terms of computational time and accuracy for solving the cure optimization problem.

stat.AP↗

arXiv2025

Constrained Bayesian Optimization under Bivariate Gaussian Process with Application to Cure Process Optimization

Bayesian Optimization, leveraging Gaussian process models, has proven to be a powerful tool for minimizing expensive-to-evaluate objective functions by efficiently exploring the search space. Extensions such as constrained Bayesian Optimization have further enhanced Bayesian Optimization's utility in practical scenarios by focusing the search within feasible regions defined by a black-box constraint function. However, constrained Bayesian Optimization in is developed based on the independence Gaussian processes assumption between objective and constraint functions, which may not hold in real-world applications. To address this issue, we use the bivariate Gaussian process model to characterize the dependence between the objective and constraint functions and developed the constrained expected improvement acquisition function under this model assumption. We show case the performance of the proposed approach with an application to cure process optimization in Manufacturing.

stat.CO↗