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The purpose of this study is to enable performing reliability-based design optimisation (RBDO) for a composite component while accounting for several multi-scale uncertainties using a large representative volume element (LRVE). This is achieved using an efficient finite element analysis (FEA)-based multi-scale reliability framework and sequential optimisation strategy.

An efficient FEA-based multi-scale reliability framework used in this study is extended and combined with a proposed sequential optimisation strategy to produce an efficient, flexible and accurate RBDO framework for fibre-reinforced composite laminate components. The proposed RBDO strategy is demonstrated by finding the optimum design solution for a composite component under the effect of multi-scale uncertainties while meeting a specific stiffness reliability requirement. Performing this using the double-loop approach is computationally expensive because of the number of uncertainties and function evaluations required to assess the reliability. Thus, a sequential optimisation concept is proposed, which starts by finding a deterministic optimum solution, then assesses the reliability and shifts the constraint limit to a safer region. This is repeated until the desired level of reliability is reached. This is followed by a final probabilistic optimisation to reduce the mass further and meet the desired level of stiffness reliability. In addition, the proposed framework uses several surrogate models to replace expensive FE function evaluations during optimisation and reliability analysis. The numerical example is also used to investigate the effect of using different sizes of LRVEs, compared with a single RVE. In future work, other problem-dependent surrogates such as Kriging will be used to allow predicting lower probability of failures with high accuracy.

The integration of the developed multi-scale reliability framework with the sequential RBDO optimisation strategy is proven computationally feasible, and it is shown that the use of LRVEs leads to less conservative designs compared with the use of single RVE, i.e. up to 3.5% weight reduction in the case of the 1 × 1 RVE optimised component. This is because the LRVE provides a representation of the spatial variability of uncertainties in a composite material while capturing a wider range of uncertainties at each iteration.

Fibre-reinforced composite laminate components designed using reliability and optimisation have been investigated before. Still, they have not previously been combined in a comprehensive multi-scale RBDO. Therefore, this study combines the probabilistic framework with an optimisation strategy to perform multi-scale RBDO and demonstrates its feasibility and efficiency for an fibre reinforced polymer component design.

The aim of this paper is to present a novel multifactor structural optimisation method incorporating reliability performance.

This research addresses structural optimisation problems in which the design is required to satisfy multiple performance criteria, such as strength, stiffness, mass and reliability under multiple loading cases simultaneously. A MOST technique is extended to accommodate the reliability‐related optimisation. Structural responses and geometrical sensitivities are analysed by a FE method, and reliability performance is calculated by a reliability loading‐case index (RLI). The evaluation indices of performances and loading cases are formulated, and an overall performance index is presented to quantitatively evaluate a design.

The proposed method is applicable to multi‐objective, multi‐loading‐case, multi‐disciplinary and reliability‐related optimisation problems. The applications to a star‐like truss structure and a raised‐access floor panel structure confirmed that the method is highly effective and efficient in terms of structural optimisation.

A systematic method is proposed. The optimisation method combines the MOST technique with a RLI (a new alternative route to calculate the reliability index at multiple loading cases) using a parametric FE model.

Mechanical products usually require deterministic finite element analysis in the design phase to determine whether their structures meet the requirements. However, deterministic design ignores the influence of uncertainties in the design and manufacturing process of mechanical products, leading to the problem of a lack of design safety or excessive redundancy in the design. In order to improve the accuracy and rationality of the design results, a robust design method for structural reliability based on an active-learning marine predator algorithm (MPA)–backpropagation (BP) neural network is proposed.

The MPA was used to obtain the optimal weights and thresholds of a BP neural network, and an active-learning function applicable to neural networks was proposed to efficiently improve the prediction performance of the BP neural network. On this basis, a robust optimization design method for mechanical product reliability based on the active-learning MPA-BP model was proposed. Random moving quadrilateral sampling was used to obtain the sample points required for training and testing of the neural network, and the reliability sensitivity corresponding to each sample point was calculated by subset simulated significant sampling (SSIS). The total mass of the mechanical product and the structural reliability sensitivity of the trained active-learning MPA-BP model output were taken as the optimization objectives, and a multi-objective reliability-robust optimization design model was constructed, which was solved by the second-generation non-dominated ranking genetic algorithm (NSGA-II). Then, the dominance function was used in the obtained Pareto solution set to make a dominance-seeking decision to obtain the final reliability-robust optimization design solution. The feasibility of the proposed method was verified by a reliability-robust optimization design example of the bogie frame.

The prediction error of the active-learning MPA-BP neural network was smaller than those of the particle swarm optimization (PSO)-BP, marine predator algorithm (MPA)-BP and genetic algorithm (GA)-BP neural networks under the same basic parameter settings of the algorithm, which indicated that the improvement strategy proposed in this paper improved the prediction accuracy of the BP neural network. To ensure the reliability of the bogie frame, the reliability sensitivity and total mass of the bogie frame were reduced, which not only realized the lightweight design of the bogie frame, but also improved the reliability and robustness of the bogie.

The MPA algorithm with a higher optimization efficiency was introduced to find the weights and thresholds of the BP neural network. A new active-learning function was proposed to improve the prediction accuracy of the MPA-BP neural network.

Meta-model method has been widely used in structural reliability optimization design. The main limitation of this method is that it is difficult to quantify the error caused by the meta-model approximation, which leads to the inaccuracy of the optimization results of the reliability evaluation. Taking the local high efficiency of the proxy model, this paper aims to propose a local effective constrained response surface method (LEC-RSM) based on a meta-model.

The operating mechanisms of LEC-RSM is to calculate the index of the local relative importance based on numerical theory and capture the most effective area in the entire design space, as well as selecting important analysis domains for sample changes. To improve the efficiency of the algorithm, the constrained efficient set algorithm (ESA) is introduced, in which the sample point validity is identified based on the reliability information obtained in the previous cycle and then the boundary sampling points that violate the constraint conditions are ignored or eliminated.

The computational power of the proposed method is demonstrated by solving two mathematical problems and the actual engineering optimization problem of a car collision. LEC-RSM makes it easier to achieve the optimal performance, less feature evaluation and fewer algorithm iterations.

This paper proposes a new RSM technology based on proxy model to complete the reliability design. The originality of this paper is to increase the sampling points by identifying the local importance of the analysis domain and introduce the constrained ESA to improve the efficiency of the algorithm.

Structural optimisation and reliability theory are considered, and described. A general reliability‐based structural optimisation problem is formulated, and consideration given to procedures for solving it. Two different examples suggest the efficacy of these procedures. The amount of calculations depends to a great degree on the definition of failure of the structure. In order to reduce this by improving optimisation procedures, more research is needed, and the convergence of the optimisation is very dependent on accurate evaluation of the gradients of the reliability constraints.

System reliability optimisation in today’s world is critical to ensuring customer satisfaction, businesses competitiveness, secure and uninterrupted delivery of services and safety of operations. Among many systems configurations, complex systems are the most difficult to model for reliability optimisation. The purpose of this paper is to assess the performance of a novel optimisation methodology of the authors, developed to address the difficulties in the context of a gas carrying system (GCS) exhibiting dual failure modes and high initial reliability.

The minimum cut sets involving components of the system were obtained using the fault tree approach, and their reliability constituted into criteria which were maximised and the associated cost of improving their reliabilities minimised. Pareto optimal generic components and system reliabilities were subsequently obtained.

The results indicate that the optimisation methodology could improve the system’s reliability even from an initially high one, granted that the feasibility factor for improving a component’s reliability was very high. The results obtained, in spite of the size (41 objective functions and 18 decision variables), the complexity (dual failure modes) and the high initial reliability values provide confidence in the optimisation model and methodology and demonstrate their applicability to systems exhibiting multiple failure modes.

The GCS was assumed either failed or operational, its parameters precisely determined, and non-repairable. The components failure rates were exponentially distributed and failure modes independent. A single weight vector representing expression of preference in which components reliabilities were weighted higher than cost was used due to the stability of the optimisation model to weight variations.

The high initial reliability values imply that reliability improvement interventions may not be a critical requirement for the GCS. The high levels could be sustained through planned and systematic inspection and maintenance activities. Even so, purely from an analytical stand point, the results nevertheless show that there was some room for reliability improvement however marginal that is. The improvement may be secured by: use of components with comparable levels of reliability to those achieved; use of redundancy techniques to achieve the desired levels of improvement in reliability; or redesigning of the components.

The novelty of this work is in the use of a reliability optimisation model and methodology that focuses on a system’s minimum cut sets as criteria to be optimised in order to optimise the system’s reliability, and the specific application to a complex system exhibiting dual failure modes and high component reliabilities.

The purpose of this paper is to formulate the reliability optimization problem in stochastic and interval domain and also to solve the same under different stochastic set up.

Stochastic programming technique has been used to convert the chance constraints into deterministic form and the corresponding problem is transformed to mixed-integer constrained optimization problem with interval objective. Then the reduced problem has been converted to unconstrained optimization problem with interval objective by Big-M penalty technique. The resulting problem has been solved by advanced real coded genetic algorithm with interval fitness, tournament selection, intermediate crossover and one-neighbourhood mutation.

A new optimization technique has been developed in stochastic domain and the concept of interval valued parameters has been integrated with the stochastic setup so as to increase the applicability of the resultant solution to the interval valued nonlinear optimization problems.

The concept of probability distribution with interval valued parameters has been introduced. This concept will motivate the researchers to carry out the research in this new direction.

The application of genetic algorithm is extended to solve the reliability optimization problem in stochastic and interval domain.

The purpose of this paper is to propose a novel non-probabilistic reliability-based topology optimization (NRBTO) method for continuum structural design under interval uncertainties of load and material parameters based on the technology of 3D printing or additive manufacturing.

First, the uncertainty quantification analysis is accomplished by interval Taylor extension to determine boundary rules of concerned displacement responses. Based on the interval interference theory, a novel reliability index, named as the optimization feature distance, is then introduced to construct non-probabilistic reliability constraints. To circumvent convergence difficulties in solving large-scale variable optimization problems, the gradient-based method of moving asymptotes is also used, in which the sensitivity expressions of the present reliability measurements with respect to design variables are deduced by combination of the adjoint vector scheme and interval mathematics.

The main findings of this paper should lie in that new non-probabilistic reliability index, i.e. the optimization feature distance which is defined and further incorporated in continuum topology optimization issues. Besides, a novel concurrent design strategy under consideration of macro-micro integration is presented by using the developed RBTO methodology.

Uncertainty propagation analysis based on the interval Taylor extension method is conducted. Novel reliability index of the optimization feature distance is defined. Expressions of the adjoint vectors between interval bounds of displacement responses and the relative density are deduced. New NRBTO method subjected to continuum structures is developed and further solved by MMA algorithms.

In order to solve the problems faced by First Order Reliability Method (FORM) and First Order Saddlepoint Approximation (FOSA) in structural reliability optimization, this paper aims to propose a new Reliability-based Design Optimization (RBDO) strategy for offshore engineering structures based on Original Probabilistic Model (OPM) decoupling strategy. The application of this innovative technique to other maritime structures has the potential to substantially improve their design process by optimizing cost and enhancing structural reliability.

In the strategy proposed by this paper, sequential optimization and reliability assessment method and surrogate model are used to improve the efficiency for solving RBDO. The strategy is applied to the analysis of two marine engineering structure cases of ship cargo hold structure and frame ring of underwater skirt pile gripper. The effectiveness of the method is proved by comparing the original design and the optimized results.

In this paper, the proposed new RBDO strategy is used to optimize the design of the ship cargo hold structure and the frame ring of the underwater skirt pile gripper. According to the results obtained, compared with the original design, the structure of optimization design has better reliability and stability, and reduces the risk of failure. This optimization can also better balance the relationship between performance and cost. Therefore, it is recommended for related RBDO problems in the field of marine engineering.

In view of the limitations of FORM and FOSA that may produce multiple MPPs for a single performance function, the new RBDO strategy proposed in this study provides valuable insights and robust methods for the optimization design of offshore engineering structures. It emphasizes the importance of combining advanced MPP search technology and integrating SORA and surrogate models to achieve more economical and reliable design.

As an advanced calculation methodology, reliability-based multidisciplinary design optimization (RBMDO) has been widely acknowledged for the design problems of modern complex engineering systems, not only because of the accurate evaluation of the impact of uncertain factors but also the relatively good balance between economy and safety of performance. However, with the increasing complexity of engineering technology, the proposed RBMDO method gradually cannot effectively solve the higher nonlinear coupled multidisciplinary uncertainty design optimization problems, which limits the engineering application of RBMDO. Many valuable works have been done in the RBMDO field in recent decades to tackle the above challenges. This study is to review these studies systematically, highlight the research opportunities and challenges, and attempt to guide future research efforts.

This study presents a comprehensive review of the RBMDO theory, mainly including the reliability analysis methods of different uncertainties and the decoupling strategies of RBMDO.

First, the multidisciplinary design optimization (MDO) preliminaries are given. The basic MDO concepts and the corresponding mathematical formulas are illustrated. Then, the procedures of three RBMDO methods with different reliability analysis strategies are introduced in detail. These RBMDO methods were proposed for the design optimization problems under different uncertainty types. Furtherly, an optimization problem for a certain operating condition of a turbine runner blade is introduced to illustrate the engineering application of the above method. Finally, three aspects of future challenges for RBMDO, namely, time-varying uncertainty analysis; high-precision surrogate models, and verification, validation and accreditation (VVA) for the model, are discussed followed by the conclusion.

The scope of this study is to introduce the RBMDO theory systematically. Three commonly used RBMDO-SORA methods are reviewed comprehensively, including the methods' general procedures and mathematical models.