Forward Gradients for Data-Driven CFD Wall Modeling

Computational Fluid Dynamics (CFD) is used in the design and optimization of gas turbines and many other industrial/ scientific applications. However, the practical use is often limited by the high computational cost, and the accurate resolution of near-wall flow is a significant contributor to this cost. Machine learning (ML) and other data-driven methods can complement existing wall models. Nevertheless, training these models is bottlenecked by the large computational effort and memory footprint demanded by back-propagation. Recent work has presented alternatives for computing gradients of neural networks where a separate forward and backward sweep is not needed and storage of intermediate results between sweeps is not required because an unbiased estimator for the gradient is computed in a single forward sweep. In this paper, we discuss the application of this approach for training a subgrid wall model that could potentially be used as a surrogate in wall-bounded flow CFD simulations to reduce the computational overhead while preserving predictive accuracy.

A Physics-Constrained NeuralODE Approach for Robust Learning of Stiff Chemical Kinetics

The high computational cost associated with solving for detailed chemistry poses a significant challenge for predictive computational fluid dynamics (CFD) simulations of turbulent reacting flows. These models often require solving a system of coupled stiff ordinary differential equations (ODEs). While deep learning techniques have been experimented with to develop faster surrogate models, they often fail to integrate reliably with CFD solvers. This instability arises because deep learning methods optimize for training error without ensuring compatibility with ODE solvers, leading to accumulation of errors over time. Recently, NeuralODE-based techniques have offered a promising solution by effectively modeling chemical kinetics. In this study, we extend the NeuralODE framework for stiff chemical kinetics by incorporating mass conservation constraints directly into the loss function during training. This ensures that the total mass and the elemental mass are conserved, a critical requirement for reliable downstream integration with CFD solvers. Our results demonstrate that this enhancement not only improves the physical consistency with respect to mass conservation criteria but also ensures better robustness and makes the training process more computationally efficient.

An automated machine learning-genetic algorithm (AutoML-GA) approach for efficient simulation-driven engine design optimization

In recent years, the use of machine learning techniques as surrogate models for computational fluid dynamics (CFD) simulations has emerged as a promising method for reducing the computational cost associated with engine design optimization. However, such methods still suffer from drawbacks. One main disadvantage of such methods is that the default machine learning hyperparameters are often severely suboptimal for a given problem. This has often been addressed by manually trying out different hyperparameter settings, but this solution is ineffective in a high-dimensional hyperparameter space. Besides this problem, the amount of data needed for training is also not known a priori. In response to these issues which need to be addressed, this work describes and validates an automated active learning approach for surrogate-based optimization of internal combustion engines, AutoML-GA. In this approach, a Bayesian optimization technique is used to find the best machine learning hyperparameters based on an initial dataset obtained from a small number of CFD simulations. Subsequently, a genetic algorithm is employed to locate the design optimum on the surrogate surface trained with the optimal hyperparameters. In the vicinity of the design optimum, the solution is refined by repeatedly running CFD simulations at the projected optimum and adding the newly obtained data to the training dataset. It is shown that this approach leads to a better optimum with a lower number of CFD simulations, compared to the use of default hyperparameters. The developed approach offers the advantage of being a more hands-off approach that can be easily applied by researchers and engineers in industry who do not have a machine learning background.

A novel machine learning-based optimization algorithm (ActivO) for accelerating simulation-driven engine design

A novel design optimization approach (ActivO) that employs an ensemble of machine learning algorithms is presented. The proposed approach is a surrogate-based scheme, where the predictions of a weak leaner and a strong learner are utilized within an active learning loop. The weak learner is used to identify promising regions within the design space to explore, while the strong learner is used to determine the exact location of the optimum within promising regions. For each design iteration, exploration is done by randomly selecting evaluation points within regions where the weak learner-predicted fitness is high. The global optimum obtained by using the strong learner as a surrogate is also evaluated to enable rapid convergence once the most promising region has been identified. First, the performance of ActivO was compared against five other optimizers on a cosine mixture function with 25 local optima and one global optimum. In the second problem, the objective was to minimize indicated specific fuel consumption of a compression-ignition internal combustion (IC) engine while adhering to desired constraints associated with in-cylinder pressure and emissions. Here, the efficacy of the proposed approach is compared to that of a genetic algorithm, which is widely used within the internal combustion engine community for engine optimization, showing that ActivO reduces the number of function evaluations needed to reach the global optimum, and thereby time-to-design by 80%. Furthermore, the optimization of engine design parameters leads to savings of around 1.9% in energy consumption, while maintaining operability and acceptable pollutant emissions.

Application of a novel machine learning based optimization algorithm (ActivO) for accelerating simulation-driven engine design

A novel design optimization approach (ActivO) that employs an ensemble of machine learning algorithms is presented. The proposed approach is a surrogate-based scheme, where the predictions of a weak leaner and a strong learner are utilized within an active learning loop. The weak learner is used to identify promising regions within the design space to explore, while the strong learner is used to determine the exact location of the optimum within promising regions. For each design iteration, exploration is done by randomly selecting evaluation points within regions where the weak learner-predicted fitness is high. The global optimum obtained by using the strong learner as a surrogate is also evaluated to enable rapid convergence once the most promising region has been identified. The proposed approach is tested on two optimization problems. The first is a cosine mixture test problem with 25 local optima and one global optimum. In the second problem, the objective is to minimize indicated specific fuel consumption of a compression-ignition internal combustion (IC) engine while adhering to desired constraints associated with in-cylinder pressure and emissions, by finding the optimal combination of nine design parameters relating to fuel injection, thermodynamic conditions, and in-cylinder flow. The efficacy of the proposed approach is compared to that of a genetic algorithm, which is widely used within the IC engine community for engine optimization, showing that ActivO reduces the number of function evaluations needed to reach the global optimum, and thereby time-to-design by 80%.