Sample-efficient and surrogate-based design optimization of underwater vehicle hulls

Physics simulations like computational fluid dynamics (CFD) are a computational bottleneck in computer- aided design (CAD) optimization processes. To overcome this bottleneck, one requires either an optimization framework that is highly sample-efficient, or a fast data-driven proxy (surrogate model) for long-running simulations. Both approaches have benefits and limitations. Bayesian optimization is often used for sample efficiency, but it solves one specific problem and struggles with transferability; alternatively, surrogate models can offer fast and often more generalizable solutions for CFD problems, but gathering data for and training such models can be computationally demanding. In this work, we leverage recent advances in optimization and artificial intelligence (AI) to explore both of these potential approaches, in the context of designing an optimal unmanned underwater vehicle (UUV) hull. For first approach, we investigate and compare the sample efficiency and convergence behavior of different optimization techniques with a standard CFD solver in the optimization loop. For the second approach, we develop a deep neural network (DNN) based surrogate model to approximate drag forces that would otherwise be computed via the CFD solver. The surrogate model is in turn used in the optimization loop of the hull design. Our study finds that the Bayesian Optimization- Lower Condition Bound (BO-LCB) algorithm is the most sample-efficient optimization framework and has the best convergence behavior of those considered. Subsequently, we show that our DNN-based surrogate model predicts drag force on test data in tight agreement with CFD simulations, with a mean absolute percentage error (MAPE) of 1.85%. Combining these results, we demonstrate a two-orders-of-magnitude speedup (with comparable accuracy) for the design optimization process when the surrogate model is used. To our knowledge, this is the first study applying Bayesian optimization and DNN-based surrogate modeling to the problem of UUV design optimization, and we share our developments as open-source software.