Assessment of an Optimal Design Method for a High-Energy Ultrasonic Igniter Based on Multi-Objective Robustness Optimization

The current deterministic optimization design method ignores uncertainties in the material properties and potential machining error which could lead to unreliable or unstable designs. To improve the design efficiency and anti-jamming ability of a high-energy ultrasonic igniter, a Six Sigma multi-objective robustness optimization design method based on the response surface model and the design of the experiment has been proposed. In this paper, the initial structural dimensions of a high-energy ultrasonic igniter have been obtained by employing one-dimensional longitudinal vibration theory. The finite element simulation method of COMSOL Multiphysics software has been verified by the finite element simulation results of ANSYS Workbench software. The optimal igniter design has been achieved by using the proposed method, which is based on the finite element method, the Optimal Latin Hypercube Design method, Grey Relational Analysis, the response surface model, the non-dominated sorting genetic algorithm, and the mean value method. Considering the influence of manufacturing errors on the igniter's performance, the Six Sigma method was used to optimize the robustness of the igniter. The Eigenfrequency analysis and the vibration velocity ratio calculation were conducted to verify the design's effectiveness. The results reveal that the longitudinal resonant frequency of the deterministic optimization scheme and the robustness optimization scheme are closer to the design's target frequency. The relative error is less than 0.1%. Compared with the deterministic optimization scheme, the vibration velocity ratio of the robustness optimization scheme is 2.8, which is about 15.7% higher than that of the deterministic optimization scheme, and the quality level of the design targets is raised to above Six Sigma. The proposed method can provide an efficient and accurate optimal design for developing a new special piezoelectric transducer.