Development of intelligent interpolation models based on limited and expensive CFD and FEA simulations for real-time applications

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The objective of this research project is to develop advanced and cheap-to-evaluate interpolation models that emulate the expensive computational fluid dynamics (CFD) and finite element analysis (FEA) solvers incorporated in a patented physics-based component life prediction tool called XactLIFE system developed in-house by the industrial partner (LPTi- Life Prediction Technologies Inc.). LPTi provides prognostics based life cycle management services for gas turbine engine parts utilizing the XactLIFE system. Going forward as part of a new product offering to their clients, LPTi aims to custom build the XactLIFE system for specific engines (with preselected critical parts). This would need the substitution of the CFD and FEA solvers present in the XactLIFE system with interpolation models to achieve real-time simulation and to avoid the need for embedding expensive CFD and FEA solvers in the customized engine specific XactLIFE systems. The proposed interpolation models will be developed utilizing computational intelligence techniques by the research team from the University of Waterloo in close collaboration with the technical experts and engineers from the industrial partner. The interpolation models will be trained with simulation results corresponding to a limited set of operating conditions (defining an envelop) and then they will be used to predict the results for any operating condition within the envelop in real-time. This research project will significantly impact the capability and range of application for the XactLIFE system in terms of its efficient and cost-effective applications to various industries for predictive maintenance of engine components and mechanical structures. The success of this project will enable the industrial partner to create new source of revenue generation and reach out to new clientele.