Article Using the Kriging Response Surface Method for the Estimation of Failure Values of Carbon-Fibre-Epoxy Subsea Composite Flowlines under the Influence of Stochastic Processes Yihan Xing 1, * , Wenxin Xu 1 and Valentina Buratti 2 1 2 * Citation: Xing, Y.; Xu, W.; Buratti, V. Using the Kriging Response Surface Method for the Estimation of Failure Department of Mechanical and Structural Engineering and Materials Science, Faculty of Science and Technology, University of Stavanger, 4021 Stavanger, Norway; xuwenxin956401@outlook.com Aibel AS, 4313 Sandnes, Norway; valentina.buratti@aibel.com Correspondence: yihan.xing@uis.no Abstract: This paper investigates the use of the Kriging response surface method to estimate failure values in carbon-fibre-epoxy composite flow-lines under the influence of stochastic processes. A case study of a 125 mm flow-line was investigated. The maximum stress, Tsai-Wu and Hashin failure criteria was used to assess the burst design under combined loading with axial forces, torsion and bending moments. An extensive set of measured values was generated using Monte Carlo simulation and used as the base case population to which the results from the response surfaces was compared. The response surfaces were evaluated in detail in their ability to reproduce the statistical moments, probability and cumulative distributions and failure values at low probabilities of failure. In addition, the optimisation of the response surface calculation was investigated in terms of reducing the number of input parameters and size of the response surface. Finally, a decision chart that can be used to build a response surface to calculate failures in a carbon fibre-epoxy-composite (CFEC) flow-line was proposed based on the findings obtained. The results show that the response surface method is suitable and can calculate failure values close to that calculated using a large set of measured values. The results from this paper provide an analytical framework for identifying the principal design parameters, response surface generation, and failure prediction for CFEC flow-lines. Values of Carbon-Fibre-Epoxy Subsea Composite Flowlines under the Keywords: composite material; kriging; response surface; optimisation; failure analysis Influence of Stochastic Processes. Designs 2022, 6, 1. https://doi.org/ 10.3390/designs6010001 Academic Editor: Julian D. Booker Received: 19 November 2021 Accepted: 21 December 2021 Published: 23 December 2021 Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. Copyright: © 2021 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https:// creativecommons.org/licenses/by/ 4.0/). 1. Introduction Subsea flow-lines play a vital role in the subsea system. They transport production/injection fluids from subsea wells to subsea manifolds, and vice versa. A higher number of deep-water oil and gas reservoirs are exploited in recent developments experienced in the oil and gas industry. This increased the average depth of oil wells drilled from 1108 m in 1949, and to 1818 m in 2008 [1]. At the same time, the oil and gas trunk pipeline’s total length was expected to increase from 1.9 million km to 2.2 million km between 2019 and 2023 [2]. This increase in distance and water depth would lead to higher associated capital and operating costs. The average pipeline cost increased from $94,000 per inch-mile in 2011 to $155,000 per inch-mile in 2002, according to ICF International [3]. One cost-effective solution gaining popularity in the subsea industry is to utilise composite materials instead of the traditionally used steel material for the subsea flow-line. Several projects that have utilised composite flow-lines are Alder, Åsgard, and West Lutong fields. Composite material has long been utilised in the aerospace and automotive industries for various applications. Some applications include using it for components such as the aircraft tail, wings and propellers, boat and scull hulls, storage tanks. They are sought after for the high strength-to-weight ratio and the customizable material directional strength properties, which can be adjusted by designing the laminate layout according to the intended application. Composite materials are not new in the subsea industry. They have been utilised Designs 2022, 6, 1. https://doi.org/10.3390/designs6010001 https://www.mdpi.com/journal/designs Designs 2022, 6, 1 2 of 28 to make subsea protection covers and ROV buckets. Their corrosion resistance properties, in addition to their strength properties, make them particularly attractive in the offshore and subsea oil and gas industry. These properties make composite materials an attractive choice in high-performance subsea flow-line applications where long reaches, deep waters, high loads and high temperatures are encountered. Carbon-fibre epoxy composite (CFEC), which consists of an epoxy matrix with carbon fibres, is a commonly used composite material when a high strength to weight ratio is desired. The epoxy matrix protects the fibres from the external environment and transfers the load between the fibres, while the fibres provide strength and stiffness to the component. As presented in Table 1, CFEC is nearly five times lighter and two times stronger than steel. This allows CFEC structures to carry larger loads than metal structures of the same weight. Moreover, as with all composite materials, the excellent corrosion properties make CFEC suitable for use in harsh environments such as subsea oil and gas applications. The epoxy carbon UD in Table 1 has a fibre volume fraction (FVF) of 60%. Table 1. Comparison of epoxy carbon UD (230GPa) and steel AISI 4130. Epoxy carbon UD Steel, AISI 4130 Yield Strength (GPa) Ultimate Tensile Strength (GPa) Density (g/cm3 ) Strength to Weight Ratio 0.95 2.231 1.11 1.49 7.85 1.497 0.141 The anisotropic nature of CFEC materials demands very comprehensive and robust stress analyses. Various authors have published several pipeline stress analysis studies. Some examples include Yang [4], who analysed the stresses at composite pipe joints under tensile loading, and Jha et al. [5], who investigated the stresses in composite flexibles for deep-water applications. Due to the complex subsea terrain, current and other factors, the subsea CEFC flow-line experiences complex combined loading. In addition, the joint action of random parameters from loads, materials, and geometry means that it may be necessary to apply stochastic models in engineering design. Some authors have previously presented stochastic processes used in pipeline engineering problems. These include Bazan et al. [6], who studied stochastic processes to predict corrosion growth in pipelines, and Oliveira et al. [7], who used the probabilistic analysis method to investigate the collapse pressure of corroded pipelines. However, applying stochastic considerations in engineering design problems is typically not widely adopted. This is mainly because it requires a large sample size, i.e., a large set of realisation values. This involves time resources which can be valuable in engineering projects. The response surface methodology is an approach that calculates an approximate result based on a response surface. The response surface is modelled by sample results calculated from simulations or measured in real life. This method requires fewer samples than the traditional approach when applied in stochastic structural analysis. Some examples of response surface methods used in engineering problems are presented here. Jia et al. [8] studied the Kriging-base response surface application in structure reliability. Simpson et al. [9] performed a comparison of the response surface and Kriging models when utilised in multidisciplinary design optimisation. Gupta et al. [10] suggested a response surface method that was improved using failure probability determination. These studies showed that the response surface is a convenient engineering analysis and optimisation tool. However, the utilisation of the response surface does require careful consideration since the response results are approximate. Many factors affect accuracy. These include the response surface type, chosen parameters, refinement method, etc. To the authors’ knowledge, there have been no prior studies using response surfaces as a tool to calculate failure values for CEFC flow-lines in a more efficient manner. This paper studies the influence of stochastic processes on the Kriging response surface method to predict failure rates in a CFEC flow-line subjected to combined loading. The Tsai-Wu [11], maximum stress and Hashin [12] failure criteria were used to quantify failure of the composite material. An extensive set of measured values was generated using Monte Carlo Designs 2022, 6, 1 3 of 28 simulation and used as the base case population to which the results from the response surfaces were compared. The response surfaces were evaluated in detail in their ability to reproduce the statistical moments, probability and cumulative distributions and failure values at low probabilities of failure. In addition, the optimisation of the response surface calculation was investigated in terms of reducing the number of input parameters and size of the response surface. Finally, a decision chart that can be used to build a response surface to calculate failures in a CFEC flow-line was proposed based on the findings obtained. The modelling and the design optimisation were performed using ANSYS Composite Pre/Post, Mechanical and DesignXplorer [13]. 2. Preliminaries 2.1. Failure Criteria Failure criteria are used in engineering to evaluate structural integrity. Generally, failure criteria compare the stresses experienced by structure to their allowable stress values. When the ratio between the two stresses is larger than 1, the component is usually considered to fail. Composite materials’ failure criteria can be grouped into two categories: (i) non-interactive failure criteria and (ii) interactive failure criteria. Non-interactive failure criteria, as the name suggests, assumes no interaction between stress or strain tensor components, i.e., the tensor components are evaluated individually. One example is the maximum stress criterion. In contrast, Tsai-Wu [11] and Hashin [12] are two examples of interactive failure criteria. Interactive failure criteria describe the failure value as a combined function of the stress or strain tensor components. The three failure criteria mentioned above were chosen to study the burst design of the CFEC flow-line in this paper. It is noted that since the classical laminate theory is used, the stresses component in the z-direction was neglected, i.e., σ3 = τ 23 = τ 13 = 0 in the following sections. 2.1.1. Maximum Stress Failure Criterion The maximum stress failure criterion is a conservative and commonly used criterion for composite materials [14]. The failure occurs when the stresses in any principle direction exceed the material strength in that direction. The failure value is calculated using Equation (1). σ1 σ2 σ3 τ12 τ13 τ23 , , , , , f = max (1) X Y Z S R Q where: σuc1 , σ1 < 0 , S = τu12 σut1 , σ1 ≥ 0 σuc2 , σ2 < 0 , R = τu13 σut2 , σ2 ≥ 0 X= Y= Z= (2) σuc3 , σ3 < 0 , Q = τu23 σut3 , σ3 ≥ 0 2.1.2. Tsai-Wu Failure Criterion The Tsai-Wu failure criterion [11] is based on the work of Gol’denblat and Koponov [15]. The criterion assumes the existence of a failure surface and distinguishes between the compressive and tensile strength in the ply failure prediction. The failure criterion uses the following quadratic formulation presented in Equation (3). 2 σ12 τ12 σ22 1 1 1 1 f = + + + σ1 − + σ2 − + 2F12 σ1 σ2 (3) σut1 σuc1 σut2 σuc2 σut1 σuc1 σut2 σuc2 τu12 2 π= Designs 2022, 6, 1 2 π12 π22 π12 1 1 1 1 + + + π1 ( − ) + π2 ( − ) ππ’π‘1 ππ’π1 ππ’π‘2 ππ’π2 ππ’12 2 ππ’π‘1 ππ’π1 ππ’π‘2 ππ’π2 + 2πΉ12 π1 π2 (3) 4 of 28 F12 is a user-specified parameter and is only associated with principle stresses σ1 and σ2. One commonly used form of F12 is presented in Equation (4). F12 is a user-specified parameter and is only associated with principle stresses σ1 and σ2 . One commonly used form of F12 is presented in Equation (4). 1 1 1 1 1 (4) πΉ12 = s − √( − )( − ) 2 π π π π 1 1 π’π‘1 1 π’π1 1π’π‘2 1π’π2 F12 = − − − (4) 2 σut1 σuc1 σut2 σuc2 F12 is also commonly obtained using bi-axial tests. Some examples can be found in F12 isetalso commonly obtained Clouston al. [16] and Li et al. [17]. using bi-axial tests. Some examples can be found in Clouston et al. [16] and Li et al. [17]. 2.1.3. Hashin Failure Criterion 2.1.3. Hashin Failure Criterion The Hashin failure criterion [12] was initially developed for unidirectional polymeric The Hashin failure criterion criterion distinguishes [12] was initially developed for unidirectional polymeric composites. The failure between three different failure modes: fibre composites. The failure criterion distinguishes between three different failure modes: fibre failure, matrix failure, and interlaminate failure, respectively. These failure modes are ilfailure, matrix failure, and interlaminate failure, respectively. These failure modes are lustrated in Figure 1. illustrated in Figure 1. Figure 1. Illustration of the various failure modes in the Hashin failure criterion. Figure 1. Illustration of the various failure modes in the Hashin failure criterion. The criterion for tensile fibre failure is presented in Equation (5). f = σ1 σut1 2 + τ12 τu12 2 , σ1 ≥ 0 (5) Designs 2022, 6, 1 5 of 28 The criterion for compressive fibre failure is presented in Equation (6). f =− σ1 , σ <0 σut1 1 (6) The criterion for tensile matrix failure is presented in Equation (7). f = σ2 σut2 2 + τ23 τu23 2 + τ12 τu12 2 + τ13 τu13 2 The criterion for compressive matrix failure is presented in Equation (8). " # 2 σuc2 2 σ2 τ23 2 τ12 2 σ2 + f = + + −1 2τu23 τu23 τu12 2τu23 σuc2 (7) (8) The criterion for tensile interlaminate failure is presented in Equation (9). f = σ3 σuc3 2 + τ13 τu13 2 + τ23 τu23 2 , σ3 < 0 (9) The criterion for compressive interlaminate failure is presented in Equation (10). f = σ3 σut3 2 + τ13 τu13 2 + τ23 τu23 2 , σ3 ≥ 0 (10) 2.1.4. Calculation of Failure Values The failure values were calculated using ANSYS Composite Pre/Post. The ACP solution then showed the failure results and the failure modes. As presented in Sections 2.1.1–2.1.3, three failure criteria have different failure modes. For the maximum stress, the failure modes are associated with σ1 , σ2 and σ3 , while the Tsai-Wu failure criteria do not distinguish between the failure modes. Hashin failure criteria are matrix failure, fibre failure and interlaminate failure. The failure values were calculated at the middle of the flow-line. 2.2. Parameter Correlation In this paper, the Spearman [18] correlation method was applied to identify the most critical parameters to be included in the response surfaces; the response surface methodology is presented in Section 2.3. The Spearman correlation method is a rankorder method that calculates the monotonic relationship between two ranked variables as presented in Equation (11). cov( gX , rgY ) (11) ρrgX,rgY = SDrgX SDrgY The calculated correlation coefficient varies from −1.0 to 1.0 and measures the statistical coupling between two parameters, x and y. The values of the computed coefficient can be interpreted as follows: • • • • • 0.0 to 0.2—Slightly correlated, the relationship is almost negligible. 0.2 to 0.4—Lowly correlated, but the relationship is definite. 0.4 to 0.6—Moderately correlated, the relationship is substantial. 0.6 to 0.8—Highly correlated, the relationship is marked 0.8 to 1.0—Very highly correlated, the relationship is very dependable A positive coefficient means that the output parameter increases when the input parameter increases, and vice versa. The correlation matrix is an n × n matrix that consists of n2 correlation coefficients describing the correlation among n design parameters. The matrix provides an overview of which parameters influence the output variables more. The Designs 2022, 6, 1 6 of 28 top 20 parameters with the highest coefficient values were included in the set of parameters used to generate the response surface model. 2.3. Response Surface Methodology Box and Wilson [19] were the first to propose the response surface methodology in 1951. They used mathematical modelling to approximate the relationship between one or more input parameters and one or more output variables. This means (Output1, Output2, . . . ) = F (Input1, Input2, . . . ) where F is the response surface. The response surface methodology is advantageous to describe model responses when the detailed function describing the input parameters to the output variables is complex and usually unknown. This is because the response surface methodology approximates the function without knowing the details. This paper’s applied response surface method is the Kriging response surface method reference [20]. It is an interpolation method that interpolates the values generated by the Gaussian process, which is governed by prior covariances. It is similar to the inverse distance weighting method, i.e., it weighs the surrounding measured values to calculate a predicted result at an unknown location. The general formula for the Kriging response surface method is presented in Equation (12). n ZΜ (s0 ) = ∑ λi ZΜ(si ) (12) i =1 where Z(si ) is the measured value at the ith location, λi is an unknown weight for the measured value at the ith location, s0 is the predicted location, and n is the number of measured values. The response surface tool in ANSYS uses the most-correlated parameters identified from the correlation matrix to generate a required size of measured values. This process is called the design of experiment. An example of a design of experiment applied to foreign object damage on 7075-T6 can be found in Arcieri et al. [21]. The central composite design method [19] was used in this paper. A larger response surface requires a larger design of experiment exercise, i.e., a more significant number of measured values. Verification points were calculated after the response surface was generated. The values from the verification points are checked against the measured values using predicted relative error values as defined in Equation (13). Predicted relative error = Predicted error × 100% Maximum known value − Minimum known value (13) where: Predicted value − Measured value (14) Measured value As observed in Equation (13), the predicted relative error is a value that is normalised by the known maximum variation of the output parameter. This allows for easy comparison across all output parameters in the design space. A predicted relative error of 5% was used in this paper. The response surface is refined iteratively with more measured values from the experiments until the predicted relative error of all output parameters falls below the threshold. Predicted error = 3. Case Study of the Burst Design of a Subsea CFEC Flowline 3.1. General Properties The flow line studied in this paper had an outer diameter, OD = 125 mm, and a wall thickness, t = 6 mm. There were 30 plies, each with a ply thickness, tply = 0.2 mm. The fibre orientation was +/−45β¦ . The material properties of the ply were taken from the Ansys material library and are presented in Table 2. The stacking sequence is illustrated in Figure 2. Designs 2022, 5, x FOR PEER REVIEW Designs 2022, 6, 1 7 of 28 7 of 28 material library and are presented in Table 2. The stacking sequence is illustrated in Figure 2. Table Table2.2.Material Materialdata—Ply data—Ply(Prepreg (PrepregEpoxy EpoxyCarbon CarbonUD UD230 230GPa). GPa). Material Property Material Property Value Symbol Symbol Value Unit Elastic Modulus E 1 , E 2 , E 3 121,000, 8600, 8600 Elastic Modulus E1 , E2 , E3 121,000, 8600, 8600 MPa ShearShear Modulus G12 , G23 , G13G12, G23, G134700, 3100, 4700 MPa Modulus 4700, 3100, 4700 Poisson’s Ratio ν , ν , ν 0.27, 0.4, 0.27 12 23 13 ν12, ν23, ν13 Poisson’s Ratio 0.27, 0.4, 0.27 Tensile Strength σut1 , σut2 , σut3 2231, 29, 29 MPa Tensile Strength σut1, σut2, σut3 2231, 29, 29 Compressive Strength σuc1 , σuc2 , σuc3 −1082, −100, −100 MPa Compressive σuc1, σuc2, σuc3 60, 32, 60 −1082, −100, −100 Shear Strength Strengthτ u12 , τ u23 , τ u13 MPa Strength 60, 32, 60 Tsai-WuShear Constants F12 , F23 , F13τu12, τu23, τu13 −1, −1, −1 Tsai-Wu Constants F12, F23, F13 −1, −1, −1 Unit MPa MPa MPa MPa MPa - Figure 2. Stacking sequence. Figure 2. Stacking sequence. 3.2. Nominal Load Values 3.2. The Nominal Loadload Values nominal values applied were an internal pressure of 6.9 MPa, an axial force of nominal load values an internal pressure an axial force 20 kN,The a torsion moment of 2 kNapplied ·m, and were a bending moment of 2 kNof ·m.6.9 AnMPa, internal pressure 20MPa kN, or a torsion of 2 kN· and a bending moment of 2 kN· m. An internal ofof6.9 69 bars moment was indicative of am,flow-line under normal operating conditions. The pressure of 6.9values MPa or 69 bars was indicative of a flow-line confailure criteria corresponding to the nominal loads are under shownnormal in Tableoperating 3. The finite ditions.model The failure values to the nominal loads are shown in Table element used criteria is described incorresponding Section 3.3. 3. The finite element model used is described in Section 3.3. Table 3. Failure values corresponding to nominal loads. Table 3. Failure values corresponding to nominal loads. Maximum Stress Failure Criterion Value Failure Mode Value Failure Criterion Failure Mode 3.3. Finite Element Model Maximum Stress 0.516 σ2 exceeded 0.516 σ2 exceeded Tsai-Wu Tsai-Wu 0.613 - 0.613 - Hashin Hashin 0.563 Matrix0.563 failure Matrix failure A long section of the flow-line measuring 2000 mm was simulated. This was considered long enough not to have any consequence from the end effects from the applied loads and boundary conditions. The results at the midpoint of the flow-line were assessed, i.e., Designs 2022, 5, x FOR PEER REVIEW 8 of 28 3.3. Finite Element Model Designs 2022, 6, 1 8 of 28 A long section of the flow-line measuring 2000 mm was simulated. This was considered long enough not to have any consequence from the end effects from the applied loads and boundary conditions. The results at the midpoint of the flow-line were assessed, i.e., thefailure failurevalues valuesatatthis thislocation locationwere wereused usedin inthe thestudy. study. The Thefinite finiteelement elementsimulations simulations the wereperformed performedusing usingANSYS ANSYSR17.0 R17.0[13]. [13]. were 3.3.1.Loads Loadsand andBoundary BoundaryConditions Conditions 3.3.1. Figure33presents presentsthe theloads loadsand andboundary boundaryconditions conditionsapplied. applied.Load LoadAAisisthe theinternal internal Figure pressure. Load B is the fixed support applied on the right edge of the flow-line. Load E is pressure. Load B is the fixed support applied on the right edge of the flow-line. Load E is the end cap force (Load E) applied on the flow-line’s left edge. Load C, Load D, and Load F the end cap force (Load E) applied on the flow-line’s left edge. Load C, Load D, and Load are axial force, torsion, and bending. They were applied to the left edge. F are axial force, torsion, and bending. They were applied to the left edge. Figure 3. Loads and Boundary Conditions. Figure 3. Loads and Boundary Conditions. 3.3.2. Mesh Refinement Study 3.3.2. Mesh Refinement The results for theStudy mesh refinement study are presented in Table 4 and Figure 4. The The results for thegiven meshin refinement study presented in Table 4 and Figure 4. The nominal load values Section 3.2 wereare used in the mesh refinement study. The nominal load values given in Section 3.2The were used in the mesh refinement study. The the 44-node SHELL181 element [13] is used. element size used in this paper was 10 mm; node [13]inisFigure used. The sizefrom usedTable in this4 paper 10 mm; the meshSHELL181 details areelement presented 5. It element is observed that anwas element size of mesh details are presented 5. It is observed fromvalues Tablefor 4 that an element of 30 mm was sufficiently fineintoFigure produce converged failure all three failure size criteria: maximum Tsai-Wu Hashin. converged failure values for all three failure crite30 mm was stress, sufficiently fineand to produce ria: maximum stress, Tsai-Wu and Hashin. Table 4. Cases studied for mesh refinement study. Table 4. Cases studied for mesh refinement study. Element Size (mm) No. of Elements Element30Size (mm) 30 25 20 25 15 20 10 515 10 5 No. of Elements 900 900 1040 1536 1040 2803 1536 6430 2803 25,344 6430 25,344 No. of Nodes No. of Nodes 912 912 1053 1552 1053 2821 1552 6432 2821 25,408 6432 25,408 Designs 2022, 5, x FOR PEER REVIEW Designs 2022, 6, 1 9 of 28 Designs 2022, 5, x FOR PEER REVIEW 9 of 28 4. Results ofstudy. mesh refinement study. Figure4.4. Results Resultsof ofFigure meshrefinement refinement study. Figure mesh Figure 5. Mesh details, 10 mm element size, 6430 SHELL181 elements with 6432 nodes. Figure Figure5.5. Mesh Meshdetails, details,10 10mm mmelement elementsize, size,6430 6430SHELL181 SHELL181elements elementswith with6432 6432nodes. nodes. 3.4. Generation of Measured Values The material parameters of Prepreg epoxy carbon UD 230 GPa were taken from the Ansys material library and used as the mean values. The standard deviation was assumed to be 3% of the mean values, i.e., the coefficient of variation was 0.03. This set of parameters 9 of Parameter Symbol Unit Mean Standard De E1 MPa 121,000 3630 Elastic Modulus E2, E3 MPa 8600 258 Designs 2022, 6, 1 10 of 28 ν12, ν13 0.27 0.0081 Poisson’s Ratio ν23 0.4 0.012 was named the base are presented in4700 Table 5. The input parameters 141 G13case in this paper and MPa Shear Modulus are normally distributed. G23 MPa 3100 93 Table 5. Mean and σ standard deviation of input parameters used in base case. ut1 MPa 2231 66.93 Tensile Strength σut2, σut3 MPa 29 0.87 Parameter Symbol Unit Mean Standard Deviation −1082 −32.46 E1 σuc1 MPa MPa 121,000 3630 Compressive Strength Elastic Modulus E2 ,σEuc2 MPa 8600 258 3 , σuc3 MPa −100 −3 ν12 , ν13 0.27 0.0081 Poisson’s Ratio τu12, τu13 1.8 ν23 - MPa 0.4 60 0.012 Shear Strength G13 MPa 4700 141 τu23 MPa 32 0.96 Shear Modulus G23 MPa 3100 93 σut1 P MPa MPa 2231 −6.9 66.93 Internal pressure −0.207 Tensile Strength σut2 , σut3 MPa 29 0.87 Axial Force 20,000 600 σuc1 A MPa N −1082 −32.46 Compressive Strength σ , σ MPa − 100 − 3 uc2 uc3B Bending N·m 2000 60 τ u12 , τ u13 MPa 60 1.8 Shear Strength Torsion 60 τ u23 T MPa N·m 32 2000 0.96 Internal pressure P MPa −6.9 −0.207 Tsai-WuAxial Constants FA12, F23, F13 0 0.3 Force N 20,000 600 Bending B D N·m mm 2000 125 60 Diameter 8.75 Torsion T N·m 2000 60 Thickness mm 0.2 0.01 Tsai-Wu Constants F12 , F23 , F13t 0 0.3 Diameter Thickness D t mm mm 125 0.2 8.75 0.01 Using the values in Table 5, the base case population of measured valu ated using Monte Carlo simulation. Examples of the cumulative probability Using the values in Table 5, the base case population of measured values was generare using plotted in Carlo Figures 6–8 for the elastic E1, diameter D and intern ated Monte simulation. Examples of the modulus cumulative probability distributions are plotted in Figures for the elastic modulus E1 , diameter D and internal rerespectively. The6–8population size was 500, chosen basedpressure on a P, convergen spectively. population sizeThe was population 500, chosen based onwas a convergence study large presented in conver sented inThe Section 3.4.1. size sufficiently that Section 3.4.1. The population size was sufficiently large that converged statistical moments moments were achieved. were achieved. Figure 6. 6. Cumulative probability distribution of elastic modulus E1 . Figure Cumulative probability distribution of elastic modulus E1. igns 2022, 5, x FOR PEER REVIEW gns 2022, 5, x FOR PEER REVIEW Designs 2022, 6, 1 11 of 28 Figure 7. Cumulative probability distribution of diameter D. Figure Cumulative probability distribution of diameter Figure 7.7.Cumulative probability distribution ofD.diameter D. Figure8.8.Cumulative Cumulative probability distribution of internalof pressure P. pressure P. Figure probability distribution internal Figure 8. Cumulative probability distribution of internal pressure P. 3.4.1. Convergence Study on Population Size 3.4.1. Convergence Convergence Study Population A convergence study was on performed to select Size a large enough population size to obtain 3.4.1. Study on Population Size converged statistical moments. Figure 9 presents the mean, standard deviation, skewness A convergence convergence study was performed performed to select a large large enough enough population andAkurtosis values versus the sample size. Figure 10to presents thea percentage difference for study was select population tain statistical moments. Figure 9 presents mean, standard devia theconverged same statistical moments compared to when the population sizethe is 500. The percentage tain converged statistical moments. Figure 9 presents the mean, standard devia difference is calculated using the formula given in Equation (15). ness and and kurtosis kurtosis values values versus versus the the sample sample size. size. Figure Figure 10 10 presents presents the the percen percen ness ence for for the the same same statistical statisticalCurrent moments the population population size size value −compared Value @ N =to 500when the ence % Difference = moments compared to when × 100% (15) Value @ Nthe = 500 percentage difference difference is is calculated calculated using formula given given in in Equation Equation (15). (15). percentage using the formula πΆπ’πππππ‘ π£πππ’π π£πππ’π − − ππππ’π ππππ’π @ @π π= = 500 500 πΆπ’πππππ‘ % Difference = × 100% 100% % Difference = × ππππ’π @ π = 500 ππππ’π @ π = 500 Designs 2022, 5, x FOR PEER REVIEW 12 of 28 Designs Designs2022, 2022,6,5,1x FOR PEER REVIEW 12 of 28 12 of 28 Figure of of moments vs. population size. size. Figure9. Values statistical moments vs.population population Figure 9.9.Values Values ofstatistical statistical moments vs. size. Figure 10. % Difference of values of statistical moments vs. population size compared to N = 500. Figure10. 10.%%Difference Differenceofofvalues valuesofofstatistical statisticalmoments momentsvs. vs.population populationsize sizecompared comparedtotoNN= =500. 500. Figure The results presented in Figures 9 and 10 show that converged statistical moments are obtained for a population size larger than 200. A population size of 500 is used in this paper. Designs 2022, 5, x FOR PEER REVIEW 13 of 28 Designs 2022, 6, 1 13 of 28 3.4.2. Fitting The results presented in Figures 9 and 10 show that converged statistical moments are obtained for a population size larger than 200. A population size of 500 is used in this paper. Statistical Models to Measured Values Statistical models fitted the results were used toValues calculate the exceedance proba3.4.2. FittingtoStatistical Models to Measured bilities, i.e., failure rates.Statistical This section presents the various statistical models used in the models fitted to the results were used to calculate the exceedance probafitting. The Matlab distribution fitting tool was used. Fourthe types of distributions, bilities, i.e., failure rates. This section presents various statistical modelsnamely used in the fitting. The Matlab distribution fitting toolfitted was used. types of distributions, namely Exponential, Weibull, Normal and Lognormal, were andFour compared with the meaExponential, Weibull, Normal and corresponding Lognormal, were fitted and compared with the meassured values, as shown in Figures 11 and 12. The R2 values are presented in ured values, as shown in Figures 11 and 12. The corresponding R2 values are presented in Table 6. As previously mentioned, the population size, i.e., the size of the set of measured Table 6. As previously mentioned, the population size, i.e., the size of the set of measured values, was 500. values, was 500. Figure 11. Statistical models fitted to measured values. Figure 11. Statistical models fitted to measured values. The results show that the Lognormal and Normal distributions fit the measured values better. In contrast, the Weibull and Exponential distributions did not fit well. Upon closer inspection of the upper tail region, as presented in Figure 12, and the R2 value, considering the tail region shown in Table 6, it is observed that the Lognormal distribution was a better fit than the Normal distribution at the upper tail region. The upper tail region is crucial for the calculation of failure rates. Therefore, the Lognormal distribution was chosen as the statistical model to be fitted to the measured values. Table 6. R2 values. Statistical Model R2 Value Exponential Lognormal Normal Weibull 0.960 0.999 0.998 0.987 Designs 2022, 6, 1 14 of 28 Designs 2022, 5, x FOR PEER REVIEW 14 of 2 Figure 12. Statistical models fitted to measured values, zoomed in at the upper tail region. Figure 12. Statistical models fitted to measured values, zoomed in at the upper tail region. Table 6. R2 values. 3.5. Calculating the Response Surface Statistical Model Exponential Lognormal 3.5.1. Parametric Correlation to Identify Most Influential Input Parameters R2 Value 0.960 0.999 Normal 0.998 Weibull 0.987 The parametric correlation matrix was calculated using the Spearman correlation method as described inThe Section to that identify the most and influential input parameters. A results2.2 show the Lognormal Normal distributions fit the measured va sample size of 100 ues wasbetter. used In in contrast, the calculation. The sample size was large enough, based the Weibull and Exponential distributions did not fit well. Upo on previous studies by the authors on upper parametric correlation matrices associated with closer inspection of the tail region, as presented in Figure 12, and the R2 value, con sidering the tail region shown in Table 6, it is observed that the Lognormal CFEC flow-lines [22]. The parametric correlation matrix is presented in Figure 13. Thedistributio was ainput better parameters fit than the Normal distribution the upper tail region. Thematrix upper tail regio twenty most influential identified from theatparametric correlation is crucial for the calculation of failure rates. Therefore, the Lognormal distribution wa are shown in Table 7. These twenty parameters were the ones with the most significant chosen as the statistical model to be fitted to the measured values. coefficients of correlation. These input parameters were used in the generation of the response surface. 3.5. Calculating the Response Surface Parameter Group Loads Geometry Material properties 3.5.1.input Parametric Correlation to Identify Most Influential Input Parameters Table 7. Most influential parameters. The parametric correlation matrix was calculated using the Spearman correlatio method as described in Section 2.2 to identify theLevel most of influential input parameters. A Parameters Correlation sample size of 100 was used in the calculation. The sample size was large enough, base P, T Moderate on previous studies by the authors on parametric correlation matrices associated wit t Moderate flow-lines matrix Slight is presented in Figure 13. Th E2 , ν12 , ν23 , ν13 , CFEC G23 , G13 , σut1 , σut3[22]. , τ u23The , D,parametric F12 , F13 , A, correlation B twenty most influential input parameters identified from the E1 , σut2 , τ u12 Lowparametric correlation ma trix are shown in Table 7. These twenty parameters were the ones with the most significan coefficients of correlation. These input parameters were used in the generation of the re sponse surface. Designs 2022, 5, x FOR PEER REVIEW Designs 2022, 6, 1 15 of 28 15 of 28 Figure 13. Parametric correlation matrix. Figure 13. Parametric correlation matrix. Table 7. Most influential input parameters. 3.5.2. Range of Input Parameters Parameter Group Level of Correlation The range of input parameters Parameters used in the generation of the response surface is Loads P, T the input parameters used Moderate presented in Table 8. As previously discussed, in the response Moderate surfaceGeometry were the top twenty most influentialt input parameters found from the parametric E2, νin12,Section ν23, ν13, 3.5.1. G23, G13, σut1, σut3, τu23, D, correlation study presented Slight Material properties F12, F13, A, B E1, σut2, τu12 Low 3.5.2. Range of Input Parameters The range of input parameters used in the generation of the response surface is presented in Table 8. As previously discussed, the input parameters used in the response surface were the top twenty most influential input parameters found from the parametric correlation study presented in Section 3.5.1. Designs 2022, 5, x FOR PEER REVIEW 16 o Designs 2022, 6, 1 16 of 28 Table 8. Range of input parameters used in response surface. Parameters Symbol Table 8. Range of input parameters used in response surface. Parameters Elastic Modulus Symbol E1 Poisson’s Ratio E2 ν12 , ν13 Poisson’s Ratio Shear Modulus ν23 G13 Shear Modulus G23 Tensile Strength σut1 Tensile Strength σut2 , σut3 Shear Strength τ u12 Shear Strength τ u23 Internal pressure Internal pressure P Axial Force Axial Force A Bending Bending B TorsionT Torsion Tsai-Wu Constants Tsai-Wu Constants F12 , F13 Diameter Diameter D Thickness t Thickness Elastic Modulus E1 Unit E2 νMPa 12, ν13 MPa ν23 G13 G23 MPa σ ut1 MPa σMPa ut2, σut3 τu12 MPa MPa τu23 MPa P MPa A N B Nm T Nm F12, F13 D mm mm t Unit Lower Limit Upper Lim MPa 108,900 133,100 Lower Upper Limit MPa Limit 7740 9460 0.243 0.297 108,900 133,100 7740 0.36 9460 0.44 0.243 MPa 4230 0.297 5170 0.36 MPa 2790 0.44 3410 4230 5170 MPa 2007.9 2454.1 2790 3410 MPa 26.12454.1 31.9 2007.9 MPa 54 31.9 66 26.1 54 MPa 28.8 66 35.2 28.8 MPa 6.21 35.2 7.59 6.21 N 18,0007.59 22,000 18,000 22,000 Nm 1800 2200 1800 2200 Nm 1800 2200 1800 2200 −1 1 1 −1 mm 100 150 150 100 0.18 mm 0.18 0.22 0.22 4. Using Response Surfaces of forFailure Prediction of Failure Rates 4. Using Response Surfaces for Prediction Rates In this the use of response surfaces for the of failure In this section, the use section, of response surfaces for the prediction of prediction failure rates is dis- rates is d cussed. The failure rate is the probability of a component having a failure value exceed cussed. The failure rate is the probability of a component having a failure value exceed1.0. The failure rate is typically decided in combination with a risk assessment. ing 1.0. The failure rate is typically decided in combination with a risk assessment. In In gene a 106 probability failure probability low, awhile a 104 failure probability is high. A higher fail general, a 106 failure is low, is while 104 failure probability is high. A higher probability can be accepted if the failure consequence is low. The benefit of using respo failure probability can be accepted if the failure consequence is low. The benefit of using surfaces is that new sampling points are calculated almost instantly after they are gen response surfaces is that new sampling points are calculated almost instantly after they ated. This provides time savings in the engineering evaluation of the design and, the c are generated. This provides time savings in the engineering evaluation of the design and, in this paper, the calculation of failure rates. The investigation was carried out as follo the case in this paper, the calculation of failure rates. The investigation was carried out as in this section. First, the statistical moments were compared between the samples gen follows in this section. First, the statistical moments were compared between the samples ated from the measured values, the response surfaces, and their corresponding fit generated from the measured values, the response surfaces, and their corresponding fitted Lognormal distributions. Second, the probability and cumulative distribution plots w Lognormal distributions. thefailure probability and cumulative distribution plots were compared.Second, Last, the rates calculated from the response surface were compa compared. Last,against the failure rates calculated from the response surface were compared the base case. The workflow process used is presented in Figure 14. against the base case. The workflow process used is presented in Figure 14. Figure 14. Workflow process. Figure 14. Workflow process. 4.1. Comparison of Statistical Moments The comparison of the statistical moments is presented in Table 9. An explanation of ”Source” in Table 9 is given in the following: • Measured values, 500 samples. These were 500 sample points calculated directly from the finite element model. These 500 samples were considered the base case population. Designs 2022, 6, 1 17 of 28 • • • • Lognormal distribution fitted to measured values: a Lognormal distribution fitted to ‘Measured values, 500 samples’. Response surface, 500 samples. These were 500 sample points calculated directly from the response surface. Lognormal distribution fitted to response surface values: a Lognormal distribution fitted to ‘Response surface, 500 samples’. The % differences were calculated with respect to ‘Measured values, 500 samples’ using Equation (16) % Difference = Current value − alue @0 Measured values, 500 samples0 × 100% Value @0 Measured values, 500 samples0 (16) Table 9. Comparison of statistical moments. Source Mean Standard Deviation Skewness Kurtosis Measured values, 500 samples 0.591 0.591 (0.0%) 0.592 (0.3%) 0.592 (0.3%) 0.039 0.039 (0.1%) 0.036 (−8.5%) 0.036 (−8.6%) 0.232 0.199 (−14.1%) 0.209 (−9.8%) 0.182 (−21.7%) 3.027 3.071 (1.4%) 2.980 (−1.6%) 3.059 (1.0%) Lognormal distribution fitted to measured values Response surface, 500 samples Lognormal distribution fitted to response surface values The following observations are made from the results presented in Table 9 • • • • There are negligible differences in the mean values. The values obtained from the response surface, when fitted to the Lognormal distribution, have smaller standard deviation values, which are about 9% smaller than the measured values. There are large differences in the skewness values. The response surface skewness values are about 10% smaller than the measured values. Fitting the response surface values to a Lognormal distribution makes the skewness values even smaller, i.e., about 22% smaller than the measured values. In addition, fitting the measured values to a Lognormal distribution gives smaller skewness values of about 14% smaller than the measured values. There are only slight differences of below 2% in the kurtosis values. 4.2. Comparison of Probability and Cumulative Distribution Plots The comparisons of the probability density and cumulative distribution plots are presented in Figures 15 and 16, respectively. The following observations are made: • • • The fitted distribution curves overlap the raw data, i.e., the measured and response surface sampled values. The response surface has a higher probability density at the most probable value; see area A in Figure 15. There are some differences in the tail regions in the cumulative probability distribution functions; see Figure 16. However, these differences are insignificant and lead to only negligible differences in the failure values calculated based on the upper tail region, as presented in Section 4.3. Designs2022, 2022,6, 5,1x FOR PEER REVIEW Designs 1818ofof28 28 Figure Comparison of probability density functions. Comparison of probability density Figure 15.15. probability density functions. functions. Figure 16. Comparison of cumulative probability distribution functions. The following observations are made: • The fitted distribution curves overlap the raw data, i.e., the measured and response surface sampled values. • The response surface has a higher probability density at the most probable value; see area A in Figure 15. •Figure There are some differences the tail regions in the functions. cumulative probability distribu16.16. Comparison of cumulative probability distribution Figure Comparison ofincumulative probability distribution functions. tion functions; see Figure 16. However, these differences are insignificant and lead to only negligible differences in the failure values calculated based on the upper tail region, presented inobservations Section 4.3. The as following are made: • • The fitted distribution curves overlap the raw data, i.e., the meas surface sampled values. The response surface has a higher probability density at the most Designs 2022, 6, 1 19 of 28 4.3. Comparison of Failure Values The comparison of failure values at three different failure rates are presented in Table 10. Table 10. Comparison of failure values. Source Lognormal distribution fitted to measured values Lognormal distribution fitted to response surface values Failure Criterion Failure Rate = 1 in 104 Failure Rate = 1 in 105 Failure Rate = 1 in 106 Maximum Stress Tsai-Wu Hashin Maximum Stress Tsai-Wu Hashin 0.64 0.75 0.76 0.64 0.74 0.75 0.67 0.78 0.79 0.66 0.77 0.78 0.69 0.81 0.81 0.68 0.79 0.80 Some notes on the large difference in the skewness values in Table 9 are made here. In general, it was harder for the skewness and kurtosis to be fitted well using an assumed probability distribution function, which in this case was the lognormal function. This is because both skewness and kurtosis are parameters that measure the shape of the probability density function. The assumed probability distribution (lognormal in this case) already has an assumed shape; therefore, it did not fit so well to the measured values at the peak region (see Figure 15). However, the failure values at different failure probability values, which are the parameters one would be concerned about within a design, are still reasonably close. This highlights that the more considerable differences in skewness did not significantly affect the results. Table 10 shows that the response surface model produced failure values that were very close to those resulting from the measured values. Therefore, it is a reliable tool for failure prediction of CEFC flow-lines under combined loading. 5. Optimising Response Surface Generation 5.1. Number of Input Parameters This section investigates the number of input parameters used to generate the response surfaces. Twenty input parameters were used in the response surface presented in Section 4. Using a smaller number of input parameters requires a smaller design of experiment, as presented in Table 11. Choosing 10 input parameters instead of 20 input parameters results in a design of experiment that is less than one-third the size, leading to significant computational savings in the generation of the response surface. In this case, the 10 most influential input parameters out of the 20 were chosen. These were the parameters with the largest coefficients of correlation. Table 11. Size of design of experiment for different numbers of input parameters. Number of Input Parameters 5 10 15 20 Size of Design of Experiment, Number of Samples Minimum Parametric Correlation Value 27 0.271 149 0.131 287 0.079 551 0.046 The effect on statistical moments, probability distributions, and predicted failure values are presented and discussed in Sections 5.1.1–5.1.3, The results show that using ten input parameters does not lead to any noticeable accuracy reduction in the calculated results. This is obvious in the case where five input parameters are used. The somewhat correlated parameters (having correlation coefficients between 0.131 to 0.271) to the failure value were excluded from generating the response surfaces. 5.1.1. Number of Parameters—Effect on Statistical Moments The statistical moments are presented in Figure 17 for the response surfaces generated with different numbers of input parameters, together with the measured values (fitted and Designs 2022, 5, x FOR PEER REVIEW Designs 2022, 6, 1 20 of 28 20 of 28 results. This is obvious in the case where five input parameters are used. The somewhat correlated parameters (having correlation coefficients between 0.131 to 0.271) to the failure value were excluded from generating the response surfaces. raw values). The corresponding differences versus the measured values are 5.1.1. Number of percentage Parameters—Effect on Statistical Moments presented in Figure 18. The following observations are made: The statistical moments are presented in Figure 17 for the response surfaces gener- • • • • ated withnot different numbers ofaffected input parameters, together with measured values (fitThe mean values were significantly when more than 10the input parameters ted and raw values). The corresponding percentage differences versus the measured valare used where the differences were within 1%. ues are presented in Figure 18. The following observations are made: The standard deviations were affected by the number of input parameters used. • The mean values were not significantly affected when more than 10 input parameters However, using the would result in a difference in the areresponse used where surface the differences werealready within 1%. standard deviation of about 9%, as presented in Section 4.1. Using smaller number • The standard deviations were affected by the number of ainput parameters used. using the this response surface would already of input parametersHowever, would increase difference to about 20%.result in a difference in the standard of about 9%, as presented in Section 4.1. Using aparameters smaller number The skewness values weredeviation significantly affected by the number of input of input parameters would increase this difference to about 20%. used. However,• using the response surface would already result in a difference in the The skewness values were significantly affected by the number of input parameters standard deviation used. of about 14%,using as presented in surface Sectionwould 4.1. Using smaller number in However, the response already aresult in a difference of input parametersthe would increase this topresented about 250%. standard deviation of difference about 14%, as in Section 4.1. Using a smaller input parameters would increase this difference to aboutparameters 250%. The kurtosis valuesnumber were of not significantly affected when enough input • The kurtosis values were not significantly affected when enough input parameters were used. However, the difference became as large as 60% when too few input were used. However, the difference became as large as 60% when too few input paparameters were used. rameters were used. Designs 2022, 5, x FOR PEER REVIEW 21 of 28 Figure 17. Number of Figure parameters—effect on statistical moments. 17. Number of parameters—effect on statistical moments. Figure 18. 18. Number Number of of parameters—effect parameters—effect on on statistical statistical moments moments (% (% difference). difference). Figure 5.1.2. Number of Parameters—Effect on Fitted Probability Distributions The probability distributions (probability density and cumulative probability) fitted to response surface values with different numbers of input parameters were plotted to- • Designs 2022, 6, 1 In general, the probability distribution functions are highly inaccurate wh number of input parameters, i.e., 5, is used. • As presented in Figure 19, the probability density functions fitted from th surfaces do not generally fit well with the measured values. 21Aofsimilar o 28 was also previously reported in Figure 15 and in Section 4.2. • As presented in Figures 20 and 21, there are some differences in the cumul 5.1.2. Number of Parameters—Effect on Fitted Probability Distributions ability distribution functions. These differences increase with decreasing The probability distributions (probability density probability) input parameters. However, these doand notcumulative significantly affectfitted thetoupper t response surface values with different numbers of input parameters were plotted together and do not lead to large differences in the failure values calculated as pr with the measured values and are presented in Figures 19–21. Section 5.1.3. Similar observations were also previously reported in Sectio Designs 2022, 5, x FOR PEER REVIEW Figure 19. Number of parameters—effect on probability density functions. 22 of 28 Figure 19. Number of parameters—effect on probability density functions. Figure 20. parameters—effect on cumulative probability functions. Figure 20.Number Numberofof parameters—effect on cumulative probability functions. Designs 2022, 6, 1 22 of 28 Figure 20. Number of parameters—effect on cumulative probability functions. Figure Figure 21. 21. Number Numberof ofparameters—effect parameters—effect on on cumulative cumulative probability probability functions functions (zoomed (zoomed in in at at upper upper tail tail region). region). 5.1.3. The Number of Parameters—Effect on Predicted Failure Values following observations are made: 12 compares the predicted failurefunctions rates calculated from the Lognormal • Table In general, the probability distribution are highly inaccurate when adistrismall butions fitted of to input response surfaces when number parameters, i.e., 5,aisdifferent used. number of input parameters was used. It• is observed frominthe results reducing the number of input parameters ten, in As presented Figure 19, that the probability density functions fitted from theto response general, do not to poor accuracy in the failure values predicted. The observation accuracy of was the surfaces dolead not generally fit well with the measured values. A similar predicted failure values suffered when 15 theand number of input also previously reported in Figure in Section 4.2. parameters was small. This • be Asexpected presentedbecause in Figures 20 and values 21, there some differences in the cumulative can the failure areare calculated from distributions fitted to probability distribution functions. These differences increase with decreasing number of input parameters. However, these do not significantly affect the upper tail regions and do not lead to large differences in the failure values calculated as presented in Section 5.1.3. Similar observations were also previously reported in Section 4.2. 5.1.3. Number of Parameters—Effect on Predicted Failure Values Table 12 compares the predicted failure rates calculated from the Lognormal distributions fitted to response surfaces when a different number of input parameters was used. It is observed from the results that reducing the number of input parameters to ten, in general, do not lead to poor accuracy in the failure values predicted. The accuracy of the predicted failure values suffered when the number of input parameters was small. This can be expected because the failure values are calculated from distributions fitted to sampled values. As previously discussed in Section 5.1.2, the number of input parameters do not affect the fitted probability distributions, unless the number of input parameters is small, i.e., 5. Designs 2022, 6, 1 23 of 28 Table 12. Number of parameters—effect on predicted failure values. Source Lognormal distribution fitted to measured values Lognormal distribution fitted to response surface values (20 input parameters) Lognormal distribution fitted to response surface values (15 input parameters) Lognormal distribution fitted to response surface values (10 input parameters) Lognormal distribution fitted to response surface values (5 input parameters) Failure Criterion Maximum Stress Tsai-Wu Hashin Maximum Stress Tsai-Wu Hashin Maximum Stress Tsai-Wu Hashin Maximum Stress Tsai-Wu Hashin Maximum Stress Tsai-Wu Hashin Failure Rate = 1 in 104 Failure Rate = 1 in 105 Failure Rate = 1 in 106 % Diff, Failure Rate = 1 in 104 % Diff, Failure Rate = 1 in 105 % Diff, Failure Rate = 1 in 106 0.64 0.67 0.69 - - - 0.75 0.76 0.78 0.79 0.81 0.81 - - - 0.64 0.66 0.68 0.0 −1.5 −1.4 0.74 0.75 0.77 0.78 0.79 0.80 −1.3 −1.3 −1.3 −1.3 −2.5 −1.2 0.64 0.67 0.69 −1.6 −3.0 −1.4 0.75 0.76 0.78 0.79 0.81 0.81 −2.7 −2.6 −2.6 −2.5 −3.7 −2.5 0.64 0.66 0.68 0.0 −1.5 −1.4 0.74 0.75 0.77 0.78 0.79 0.8 −4.0 −1.3 −5.1 −1.3 −6.2 −1.2 0.63 0.65 0.68 15.6 14.9 15.9 0.73 0.74 0.76 0.77 0.78 0.79 5.3 2.6 5.1 2.5 3.7 2.5 5.2. Size of Response Surface In this section, the effects of response surfaces sizes are studied. Two larger response surfaces were compared against the original surface size used in Sections 3, 4 and 5.1. These larger response surfaces were named ‘larger size’ and ‘extremely large size’. The number of input parameters used to generate the response surfaces was the same, i.e., 20, while the range of diameter and ply thickness is varied. The diameters and ply thicknesseses considered are presented in Table 13. Table 13. Range of diameters and ply thicknesses studied. Base Case Larger Size Extremely Larger Size Diameter (mm) Thickness (mm) 100–150 75–175 50–200 0.18–0.22 0.14–0.26 0.10–0.30 The effect on statistical moments, probability distributions, and predicted failure values are presented and discussed in Sections 5.2.1–5.2.3 The results show that the huge response surface leads to inaccurate skewness values and probability distribution functions. However, the size of the response surface does not significantly affect the upper tail regions of the probability distributions and consequently leads to only minor differences in predicted failure rates if it is not too large, as demonstrated in the ‘larger size’ response surface. 5.2.1. Size of Response Surface—Effect on Statistical Moments The statistical moments are presented in Figure 22 for the response surfaces generated with different diameter ranges and ply thickness and the measured values (fitted and raw values). The corresponding percentage differences versus the measured values are presented in Figure 23. The following observations are made: 1. 2. 3. In general, the differences in statistical moments calculated increased with the size of the response surface used. The differences in the mean values increase with the size of the response surface used but were within 10% for ‘extremely large size’. The response surface size has limited or no influence on the standard deviation values. The differences in the standard deviation are within approximately 10%, which were like that of the ‘base case’, which had 8.5%. Designs 2022, 5, x FOR PEER REVIEW Designs 2022, 5, x FOR PEER REVIEW Designs 2022, 6, 1 3. 3. 4. 4. 5. 24 of 28 24 of 28 The response responsesurface surfacesize sizehas haslimited limited influence standard deviation 24 of 28 valThe oror nono influence on on thethe standard deviation values. The differences in the standard deviation are within approximately 10%, which ues. The differences in the standard deviation are within approximately 10%, which were like like that thatof ofthe the‘base ‘basecase’, case’,which which had 8.5%. were had 8.5%. skewness is strongly affected by the response surface size. ‘larger The skewness is strongly affected by the response size. For the ‘larger size’ The skewness is strongly affected by the response surface surface size. ForFor thethe ‘larger size’size’ and ‘extremely large size’, the differences were as much as 40%. and ‘extremely ‘extremely large large size’, the differences were as much as 40%. The increased with thethe sizesize of the differences inthe thekurtosis kurtosisvalues values increased with of the response surface The differences differences in response surface used large size’. used but were within used but were werewithin within10% 10%for for‘extremely ‘extremely large size’. Figure 22. Size of response surface—effect on statistical moments. Figure 22. Size of response surface—effect on statistical moments. Figure 22. Size of response surface—effect on statistical moments. Figure 23. Size of response surface—effect on statistical moments (% difference). Figure 23. Size of response surface—effect on statistical moments (% difference). Figure 23. Size of response surface—effecton onFitted statistical moments (% difference). 5.2.2. Size of Surface—Effect on Fitted Probability Distributions 5.2.2. Size of Response Response Surface—Effect Probability Distributions The probability probabilitydistributions distributions(probability (probabilitydensity densityand andcumulative cumulative probability) fitted The probability) fitted to 5.2.2. Size ofsurface Response Surface—Effect on Fitted Probability Distributions to response values with different response surface sizes are plotted together with response surface values with different response surface sizes are plotted together with the the measured values (fitted values) presented in cumulative Figures 24–26. The probability distributions (probability density probability) fitted measured values (fitted and and raw raw values) and and presented inand Figures 24–26. are made: response surface sizes are plotted together with to response surfaceobservations values withare different The following made: the (fitted and raw values) andinin presented in Figures 24–26. •• measured In general, general,values using ‘extremely large size’results results significant differences probausing ‘extremely large size’ significant differences inin thethe probabilThe following observations are made: bility distributions. ity distributions. • • As presented in Figure 24, thelarge probability densityinfunctions fitted from the in response • In general, using ‘extremely size’ results significant differences the probasurfaces generally fit well with the measured values. The ‘extremely large size’ surfaces do not measured values. The ‘extremely large size’ bility distributions. probability distribution function is especially far away from that of the • As presented in Figure 24, the probability density functions fitted from the response measured values. surfaces do not generally fit well with the measured values. The ‘extremely large size’ • As shown in Figure 25, the cumulative probability distributions of ‘base case’ and ‘larger size’ were close to those of the measured values. Furthermore, as presented in Designs2022, 2022,5,5,xxFOR FORPEER PEERREVIEW REVIEW Designs Designs 2022, 6, 1 •• 25 of of 28 28 25 probability distribution distribution function function isis especially especially far far away away from from that that of of the the measured measured probability 25 of 28 values. values. As shown shown in in Figure Figure 25, 25, the the cumulative cumulative probability probability distributions distributions of of ‘base ‘base case’ case’ and and As ‘largersize’ size’were wereclose closeto tothose thoseof ofthe themeasured measuredvalues. values.Furthermore, Furthermore,as aspresented presentedin in ‘larger Figure26, 26,these thesedifferences differences became more minor at the upper tail regions. As observed Figure became more minor at the upper tail regions. As observed differences tail regions. As observed inthe the probability density functions, the ‘extremely large size’ cumulative probability in theprobability probabilitydensity densityfunctions, functions,the the‘extremely ‘extremelylarge largesize’ size’cumulative cumulativeprobability probability functionisisespecially especiallyfar faraway awayfrom fromthat thatof ofthe function themeasured measured values. values. Figure 24. Size of response surface—effect onprobability probabilitydensity densityfunctions. functions. Figure Figure24. 24.Size Sizeof ofresponse responsesurface—effect surface—effecton Figure25. 25.Size Sizeof ofresponse responsesurface—effect surface—effecton oncumulative cumulativeprobability probabilityfunctions. functions. Figure 25. Size of response surface—effect Figure Designs 2022, 5, x FOR PEER REVIEW Designs 2022, 6, 1 26 of 28 26 of 28 Size of of response response surface—effect surface—effect on on cumulative cumulative probability probability functions (zoomed in at upper upper Figure 26. Size tail region). 5.2.3. Size Size of of Response Response Surface—Effect Surface—Effect on on Predicted Predicted Failure 5.2.3. Failure Values Values Table 14 compares the predicted failure rates calculated from the the Lognormal Lognormal distridistriTable 14 compares the predicted failure rates calculated from butions fitted to response surfaces with different ranges of diameter and ply thickness. It butions fitted to response surfaces with different ranges of diameter and ply thickness. It is observed that the size of the response surfaces did not significantly affect the predicted is observed that the size of the response surfaces did not significantly affect the predicted failure values. values.AAlarger largerresponse response surface, general, would to more considerable failure surface, in in general, would leadlead to more considerable difdifferences in the predicted failure values. Most of the differences were below except ferences in the predicted failure values. Most of the differences were below 5% 5% except for for the Tsai-Wu failure value for the ‘extremely large size’ response surface. the Tsai-Wu failure value for the ‘extremely large size’ response surface. Table 14. Table 14. Number Number of of parameters—effect parameters—effect on on predicted predicted failure failure values. values. Source Source Failure Failure Criterion Criterion % Diff, % Diff, % Diff, Failure 1 Failure 1 Failure Failure RateRate = 1 = Failure RateRate = 1 =Failure RateRate = 1 = 1 % Diff, Failure % Diff, Failure % Diff, Failure Failure Rate = 1 Rate = 1 5 Failure Rate = 16 5 6 4 Failure in 10 in 10in in 10in in4 104 105 106 Rate Rate = Rate = 1 in 10 4= 1 in 10 51 in 10 in 10 in 10 in 106 Maximum Stress Maximum Tsai-Wu Stress Tsai-Wu Hashin to measured values Hashin Stress Lognormal distribution fitted Maximum Maximum distribution fitted to Lognormal base case response surface Tsai-Wu Stress to base case response Tsai-Wu values Hashin surface values Hashin Lognormal distribution fitted Maximum Stress Maximum Lognormal distribution fitted to larger size response Tsai-Wu Stress to larger size response Tsai-Wu surface values Hashin surface values Hashin Lognormal distribution fitted Maximum Stress Maximum fitted toLognormal extremelydistribution large response Tsai-Wu Stress to extremely large response Tsai-Wu surface Hashin surfacevalues values Lognormal distribution fitted Lognormal distribution to measured valuesfitted Hashin 0.64 0.67 0.69 0.640.75 0.67 0.78 0.69 0.81 0.750.76 0.760.64 0.78 0.79 0.79 0.66 0.81 0.81 0.81 0.68 0.640.74 0.66 0.77 0.68 0.79 0.740.75 0.75 0.77 0.78 0.78 0.79 0.80 0.80 0.630.75 0.65 0.78 0.750.75 0.75 0.78 0.77 0.77 0.67 0.81 0.81 0.80 0.80 0.630.80 0.66 0.83 0.800.76 0.76 0.83 0.79 0.79 0.63 0.63 0.65 0.66 0.67 0.67 0.67 0.85 0.85 0.81 0.81 - 0.0 0.0 −1.3 −1.3−1.3 −1.3−1.8 −1.8−0.1 −0.1−1.2 −1.2 −1.4 −1.4 5.7 5.7 0.6 - 0.6 - - - - -- - -−1.5 −1.5 −1.3 −1.3 −1.3 −1.3 −1.9 −1.9 −0.1 −0.1 −1.4 −1.4 −1.8 −1.8 5.6 5.60.4 0.4 -−1.4 −−2.5 1.4 −−1.2 2.5 −−2.1 1.2 −−0.3 2.1 −−1.5 0.3 −1.5 −2.1 −5.6 2.1 5.6 0.2 0.2 5.3. Recommendations for Optimisation of Response Surface 5.3. Recommendations for Optimisation of Response Surface Based on the findings obtained in Sections 5.1 and 5.2, the following recommendaon the obtained in 5.1 and 5.2, the following recommendations tionsBased are made forfindings the optimisation of Sections the response surface: are made for the optimisation of the response surface: • Reduce the input parameters selected to generate the response surface by only select• ing Reduce the input parameters selectedcorrelation to generatecoefficients the responsegreater surfacethan by only selecting the parameters with parametric +/−0.15. the parameters with parametric correlation coefficients greater than +/−0.15. Designs 2022, 6, 1 27 of 28 • Consider using a larger response surface to maximise flexibility if the accuracy in the predicted failure values is not extremely important. A larger response surface would lead to some decreased accuracy in the results. 6. Conclusions In this paper, the use of the Kriging response surface method for the estimation of failure values in carbon-fibre-epoxy composite flow-lines under the influence of stochastic processes was investigated. The following conclusions are made: • • • • • • In general, the response surface method produced predicted failure results close to those of the measured values. Most errors were minor unless too few input parameters are selected to generate the response surface and/or the size of the response surface was too large. The response surfaces do not accurately represent the skewness values in general; there was at least a 9% difference in the results. However, this is not of practical significance as it did not affect the prediction of failure values. In general, using more input parameters increases the accuracy of the response surface. However, it also increases the time required to generate the response surface, as the design of experiment will increase in size. It is recommended to select input parameters with correlation coefficients greater than +/−0.15, i.e., input parameters that are slightly correlated. In this present study, this results in about 10 input parameters. In general, a more extensive response surface leads to reduced accuracy. However, this enables greater flexibility in its utilisation as a more comprehensive range of input parameters is covered. The response surface enables more rapid design optimisation process than using a brute force method; the computation of the failure values is instantaneous. Author Contributions: Conceptualization, Y.X.; methodology, Y.X.; software, Y.X., W.X. and V.B.; validation, Y.X and W.X.; formal analysis, Y.X., W.X. and V.B.; investigation, Y.X., W.X and V.B.; resources, Y.X.; data curation, W.X.; writing—original draft preparation, Y.X.; writing—review and editing, Y.X.; visualization, Y.X. and W.X; supervision, Y.X. and V.B.; project administration, Y.X.; funding acquisition, Y.X. All authors have read and agreed to the published version of the manuscript. Funding: This research received no external funding. Institutional Review Board Statement: Not applicable. Informed Consent Statement: Not applicable. Data Availability Statement: Not applicable. Conflicts of Interest: The authors declare no conflict of interest. Nomenclature σh σl σ1 σ2 σ3 τ12 τ23 τ13 σuc1 σuc2 σuc3 σut1 σut2 σut3 Hoop stress Longitudinal stress Principle stress in x-direction Principle stress in y-direction Principle stress in z-direction Shear stress in xy-plane Shear stress in yz-plane Shear stress in xz-plane Compressive strength limit in x-direction Compressive strength limit in y-direction Compressive strength limit in z-direction Tensile strength limit in x-direction Tensile strength limit in y-direction Tensile strength limit in z-direction Designs 2022, 6, 1 28 of 28 τu12 τu23 τu13 ρrgX,rgY cov r gX , r gY SDrgX SDrgY D t Shear strength limit in xy-plane Shear strength limit in yz-plane Shear strength limit in xz-plane Spearman correlation coefficient Covariance of the rank variable Standard deviation of the rank variable gX Standard deviation of the rank variable gY Flow-line Diameter Flowline wall thickness References 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 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