Multi-Material Topology Optimization for Spatial-Varying Porous Structures

This paper aims to propose a topology optimization method on generating porous structures comprising multiple materials.The mathematical optimization formulation is established under the constraints of individual volume fraction of constituent phase or total mass,as well as the local volume fraction of all phases.The original optimization problem with numerous constraints is converted into a box-constrained optimization problem by incorporating all constraints to the augmented Lagrangian function,avoiding the parameter dependence in the conventional aggregation process.Furthermore,the local volume percentage can be precisely satisfied.The effects including the globalmass bound,the influence radius and local volume percentage on final designs are exploited through numerical examples.The numerical results also reveal that porous structures keep a balance between the bulk design and periodic design in terms of the resulting compliance.All results,including those for irregular structures andmultiple volume fraction constraints,demonstrate that the proposedmethod can provide an efficient solution for multiple material infill structures.

Development of Fixture Layout Optimization for Thin-Walled Parts:A Review

An increasing number of researchers have researched fixture layout optimization for thin-walled part assembly during the past decades.However,few papers systematically review these researches.By analyzing existing literature,this paper summarizes the process of fixture layout optimization and the methods applied.The process of optimization is made up of optimization objective setting,assembly variation/deformation modeling,and fixture layout optimization.This paper makes a review of the fixture layout for thin-walled parts according to these three steps.First,two different kinds of optimization objectives are introduced.Researchers usually consider in-plane variations or out-of-plane deformations when designing objectives.Then,modeling methods for assembly variation and deformation are divided into two categories:Mechanism-based and data-based methods.Several common methods are discussed respectively.After that,optimization algorithms are reviewed systematically.There are two kinds of optimization algorithms:Traditional nonlinear programming and heuristic algorithms.Finally,discussions on the current situation are provided.The research direction of fixture layout optimization in the future is discussed from three aspects:Objective setting,improving modeling accuracy and optimization algorithms.Also,a new research point for fixture layout optimization is discussed.This paper systematically reviews the research on fixture layout optimization for thin-walled parts,and provides a reference for future research in this field.

Enhancing Renewable Energy Integration:A Gaussian-Bare-Bones Levy Cheetah Optimization Approach to Optimal Power Flow in Electrical Networks

In the contemporary era,the global expansion of electrical grids is propelled by various renewable energy sources(RESs).Efficient integration of stochastic RESs and optimal power flow(OPF)management are critical for network optimization.This study introduces an innovative solution,the Gaussian Bare-Bones Levy Cheetah Optimizer(GBBLCO),addressing OPF challenges in power generation systems with stochastic RESs.The primary objective is to minimize the total operating costs of RESs,considering four functions:overall operating costs,voltage deviation management,emissions reduction,voltage stability index(VSI)and power loss mitigation.Additionally,a carbon tax is included in the objective function to reduce carbon emissions.Thorough scrutiny,using modified IEEE 30-bus and IEEE 118-bus systems,validates GBBLCO’s superior performance in achieving optimal solutions.Simulation results demonstrate GBBLCO’s efficacy in six optimization scenarios:total cost with valve point effects,total cost with emission and carbon tax,total cost with prohibited operating zones,active power loss optimization,voltage deviation optimization and enhancing voltage stability index(VSI).GBBLCO outperforms conventional techniques in each scenario,showcasing rapid convergence and superior solution quality.Notably,GBBLCO navigates complexities introduced by valve point effects,adapts to environmental constraints,optimizes costs while considering prohibited operating zones,minimizes active power losses,and optimizes voltage deviation by enhancing the voltage stability index(VSI)effectively.This research significantly contributes to advancing OPF,emphasizing GBBLCO’s improved global search capabilities and ability to address challenges related to local minima.GBBLCO emerges as a versatile and robust optimization tool for diverse challenges in power systems,offering a promising solution for the evolving needs of renewable energy-integrated power grids.

A Subdivision-Based Combined Shape and Topology Optimization in Acoustics

We propose a combined shape and topology optimization approach in this research for 3D acoustics by using the isogeometric boundary element method with subdivision surfaces.The existing structural optimization methods mainly contain shape and topology schemes,with the former changing the surface geometric profile of the structure and the latter changing thematerial distribution topology or hole topology of the structure.In the present acoustic performance optimization,the coordinates of the control points in the subdivision surfaces fine mesh are selected as the shape design parameters of the structure,the artificial density of the sound absorbing material covered on the structure surface is set as the topology design parameter,and the combined topology and shape optimization approach is established through the sound field analysis of the subdivision surfaces boundary element method as a bridge.The topology and shape sensitivities of the approach are calculated using the adjoint variable method,which ensures the efficiency of the optimization.The geometric jaggedness and material distribution discontinuities that appear in the optimization process are overcome to a certain degree by the multiresolution method and solid isotropic material with penalization.Numerical examples are given to validate the effectiveness of the presented optimization approach.

Multi-Stage Multidisciplinary Design Optimization Method for Enhancing Complete Artillery Internal Ballistic Firing Performance

To enhance the comprehensive performance of artillery internal ballistics—encompassing power,accuracy,and service life—this study proposed a multi-stage multidisciplinary design optimization(MS-MDO)method.First,the comprehensive artillery internal ballistic dynamics(AIBD)model,based on propellant combustion,rotation band engraving,projectile axial motion,and rifling wear models,was established and validated.This model was systematically decomposed into subsystems from a system engineering perspective.The study then detailed the MS-MDO methodology,which included Stage I(MDO stage)employing an improved collaborative optimization method for consistent design variables,and Stage II(Performance Optimization)focusing on the independent optimization of local design variables and performance metrics.The methodology was applied to the AIBD problem.Results demonstrated that the MS-MDO method in Stage I effectively reduced iteration and evaluation counts,thereby accelerating system-level convergence.Meanwhile,Stage II optimization markedly enhanced overall performance.These comprehensive evaluation results affirmed the effectiveness of the MS-MDO method.

Identifying influential spreaders in social networks: A two-stage quantum-behaved particle swarm optimization with Lévy flight

The influence maximization problem aims to select a small set of influential nodes, termed a seed set, to maximize their influence coverage in social networks. Although the methods that are based on a greedy strategy can obtain good accuracy, they come at the cost of enormous computational time, and are therefore not applicable to practical scenarios in large-scale networks. In addition, the centrality heuristic algorithms that are based on network topology can be completed in relatively less time. However, they tend to fail to achieve satisfactory results because of drawbacks such as overlapped influence spread. In this work, we propose a discrete two-stage metaheuristic optimization combining quantum-behaved particle swarm optimization with Lévy flight to identify a set of the most influential spreaders. According to the framework,first, the particles in the population are tasked to conduct an exploration in the global solution space to eventually converge to an acceptable solution through the crossover and replacement operations. Second, the Lévy flight mechanism is used to perform a wandering walk on the optimal candidate solution in the population to exploit the potentially unidentified influential nodes in the network. Experiments on six real-world social networks show that the proposed algorithm achieves more satisfactory results when compared to other well-known algorithms.

An Optimal Node Localization in WSN Based on Siege Whale Optimization Algorithm

Localization or positioning scheme in Wireless sensor networks (WSNs) is one of the most challenging andfundamental operations in various monitoring or tracking applications because the network deploys a large areaand allocates the acquired location information to unknown devices. The metaheuristic approach is one of themost advantageous ways to deal with this challenging issue and overcome the disadvantages of the traditionalmethods that often suffer from computational time problems and small network deployment scale. This studyproposes an enhanced whale optimization algorithm that is an advanced metaheuristic algorithm based on thesiege mechanism (SWOA) for node localization inWSN. The objective function is modeled while communicatingon localized nodes, considering variables like delay, path loss, energy, and received signal strength. The localizationapproach also assigns the discovered location data to unidentified devices with the modeled objective functionby applying the SWOA algorithm. The experimental analysis is carried out to demonstrate the efficiency of thedesigned localization scheme in terms of various metrics, e.g., localization errors rate, converges rate, and executedtime. Compared experimental-result shows that theSWOA offers the applicability of the developed model forWSNto perform the localization scheme with excellent quality. Significantly, the error and convergence values achievedby the SWOA are less location error, faster in convergence and executed time than the others compared to at least areduced 1.5% to 4.7% error rate, and quicker by at least 4%and 2% in convergence and executed time, respectivelyfor the experimental scenarios.

A modified back analysis method for deep excavation with multi-objective optimization procedure

Real-time prediction of excavation-induced displacement of retaining pile during the deep excavation process is crucial for construction safety.This paper proposes a modified back analysis method with multi-objective optimization procedure,which enables a real-time prediction of horizontal displacement of retaining pile during construction.As opposed to the traditional stage-by-stage back analysis,time series monitoring data till the current excavation stage are utilized to form a multi-objective function.Then,the multi-objective particle swarm optimization (MOPSO) algorithm is applied for parameter identification.The optimized model parameters are immediately adopted to predict the excavation-induced pile deformation in the continuous construction stages.To achieve efficient parameter optimization and real-time prediction of system behavior,the back propagation neural network (BPNN) is established to substitute the finite element model,which is further implemented together with MOPSO for automatic operation.The proposed approach is applied in the Taihu tunnel excavation project,where the effectiveness of the method is demonstrated via the comparisons with the site monitoring data.The method is reliable with a prediction accuracy of more than 90%.Moreover,different optimization algorithms,including non-dominated sorting genetic algorithm (NSGA-II),Pareto Envelope-based Selection Algorithm II (PESA-II) and MOPSO,are compared,and their influences on the prediction accuracy at different excavation stages are studied.The results show that MOPSO has the best performance for high dimensional optimization task.

Optimization Design of the Multi-Layer Cross-Sectional Layout of An Umbilical Based on the GA-GLM

Marine umbilical is one of the key equipment for subsea oil and gas exploitation,which is usually integrated by a great number of different functional components with multi-layers.The layout of these components directly affects manufacturing,operation and storage performances of the umbilical.For the multi-layer cross-sectional layout design of the umbilical,a quantifiable multi-objective optimization model is established according to the operation and storage requirements.Considering the manufacturing factors,the multi-layering strategy based on contact point identification is introduced for a great number of functional components.Then,the GA-GLM global optimization algorithm is proposed combining the genetic algorithm and the generalized multiplier method,and the selection operator of the genetic algorithm is improved based on the steepest descent method.Genetic algorithm is used to find the optimal solution in the global space,which can converge from any initial layout to the feasible layout solution.The feasible layout solution is taken as the initial value of the generalized multiplier method for fast and accurate solution.Finally,taking umbilicals with a great number of components as examples,the results show that the cross-sectional performance of the umbilical obtained by optimization algorithm is better and the solution efficiency is higher.Meanwhile,the multi-layering strategy is effective and feasible.The design method proposed in this paper can quickly obtain the optimal multi-layer cross-sectional layout,which replaces the manual design,and provides useful reference and guidance for the umbilical industry.

Synergistic Swarm Optimization Algorithm

This research paper presents a novel optimization method called the Synergistic Swarm Optimization Algorithm(SSOA).The SSOA combines the principles of swarmintelligence and synergistic cooperation to search for optimal solutions efficiently.A synergistic cooperation mechanism is employed,where particles exchange information and learn from each other to improve their search behaviors.This cooperation enhances the exploitation of promising regions in the search space while maintaining exploration capabilities.Furthermore,adaptive mechanisms,such as dynamic parameter adjustment and diversification strategies,are incorporated to balance exploration and exploitation.By leveraging the collaborative nature of swarm intelligence and integrating synergistic cooperation,the SSOAmethod aims to achieve superior convergence speed and solution quality performance compared to other optimization algorithms.The effectiveness of the proposed SSOA is investigated in solving the 23 benchmark functions and various engineering design problems.The experimental results highlight the effectiveness and potential of the SSOA method in addressing challenging optimization problems,making it a promising tool for a wide range of applications in engineering and beyond.Matlab codes of SSOA are available at:https://www.mathworks.com/matlabcentral/fileexchange/153466-synergistic-swarm-optimization-algorithm.

An Overview of Sequential Approximation in Topology Optimization of Continuum Structure

This paper offers an extensive overview of the utilization of sequential approximate optimization approaches in the context of numerically simulated large-scale continuum structures.These structures,commonly encountered in engineering applications,often involve complex objective and constraint functions that cannot be readily expressed as explicit functions of the design variables.As a result,sequential approximation techniques have emerged as the preferred strategy for addressing a wide array of topology optimization challenges.Over the past several decades,topology optimization methods have been advanced remarkably and successfully applied to solve engineering problems incorporating diverse physical backgrounds.In comparison to the large-scale equation solution,sensitivity analysis,graphics post-processing,etc.,the progress of the sequential approximation functions and their corresponding optimizersmake sluggish progress.Researchers,particularly novices,pay special attention to their difficulties with a particular problem.Thus,this paper provides an overview of sequential approximation functions,related literature on topology optimization methods,and their applications.Starting from optimality criteria and sequential linear programming,the other sequential approximate optimizations are introduced by employing Taylor expansion and intervening variables.In addition,recent advancements have led to the emergence of approaches such as Augmented Lagrange,sequential approximate integer,and non-gradient approximation are also introduced.By highlighting real-world applications and case studies,the paper not only demonstrates the practical relevance of these methods but also underscores the need for continued exploration in this area.Furthermore,to provide a comprehensive overview,this paper offers several novel developments that aim to illuminate potential directions for future research.

Long-term operation optimization of circulating cooling water systems under fouling conditions

Fouling caused by excess metal ions in hard water can negatively impact the performance of the circulating cooling water system(CCWS)by depositing ions on the heat exchanger's surface.Currently,the operation optimization of CCWS often prioritizes short-term flow velocity optimization for minimizing power consumption,without considering fouling.However,low flow velocity promotes fouling.Therefore,it's crucial to balance fouling and energy/water conservation for optimal CCWS long-term operation.This study proposes a mixed-integer nonlinear programming(MINLP)model to achieve this goal.The model considers fouling in the pipeline,dynamic concentration cycle,and variable frequency drive to optimize the synergy between heat transfer,pressure drop,and fouling.By optimizing the concentration cycle of the CCWS,water conservation and fouling control can be achieved.The model can obtain the optimal operating parameters for different operation intervals,including the number of pumps,frequency,and valve local resistance coefficient.Sensitivity experiments on cycle and environmental temperature reveal that as the cycle increases,the marginal benefits of energy/water conservation decrease.In periods with minimal impact on fouling rate,energy/water conservation can be achieved by increasing the cycle while maintaining a low fouling rate.Overall,the proposed model has significant energy/water saving effects and can comprehensively optimize the CCWS through its incorporation of fouling and cycle optimization.

An Improved JSO and Its Application in Spreader Optimization of Large Span Corridor Bridge

In this paper,given the shortcomings of jellyfish search algorithmwith low search ability in the early stage and easy to fall into local optimal solution,this paper introduces adaptive weight function and elite strategy,improving the global search scope in the early stage and the ability to refine the local development in the later stage.In the numerical study,the benchmark problem of dimensional optimization with a 10-bar truss structure and simultaneous dimensional shape optimization with a 15-bar truss structure is adopted,and the corresponding penalty method is used for constraint treatment.The test results show that the improved jellyfish search algorithm can provide better truss sections as well as weights.Because when the steel main truss of the large-span covered bridge is lifted,the site is limited and the large lifting equipment cannot enter the site,and the original structure does not meet the problem of stress concentration and large deformation of the bolt group,so the spreader is used to lift,and the improved jellyfish search algorithm is introduced into the design optimization of the spreader.The results show that the improved jellyfish algorithm can efficiently and accurately find out the optimal shape and weight of the spreader,and throughMidas Civil simulation,the spreader used canmeet the requirements of weight and safety.

Multi-surrogate framework with an adaptive selection mechanism for production optimization

Data-driven surrogate models that assist with efficient evolutionary algorithms to find the optimal development scheme have been widely used to solve reservoir production optimization problems.However,existing research suggests that the effectiveness of a surrogate model can vary depending on the complexity of the design problem.A surrogate model that has demonstrated success in one scenario may not perform as well in others.In the absence of prior knowledge,finding a promising surrogate model that performs well for an unknown reservoir is challenging.Moreover,the optimization process often relies on a single evolutionary algorithm,which can yield varying results across different cases.To address these limitations,this paper introduces a novel approach called the multi-surrogate framework with an adaptive selection mechanism(MSFASM)to tackle production optimization problems.MSFASM consists of two stages.In the first stage,a reduced-dimensional broad learning system(BLS)is used to adaptively select the evolutionary algorithm with the best performance during the current optimization period.In the second stage,the multi-objective algorithm,non-dominated sorting genetic algorithm II(NSGA-II),is used as an optimizer to find a set of Pareto solutions with good performance on multiple surrogate models.A novel optimal point criterion is utilized in this stage to select the Pareto solutions,thereby obtaining the desired development schemes without increasing the computational load of the numerical simulator.The two stages are combined using sequential transfer learning.From the two most important perspectives of an evolutionary algorithm and a surrogate model,the proposed method improves adaptability to optimization problems of various reservoir types.To verify the effectiveness of the proposed method,four 100-dimensional benchmark functions and two reservoir models are tested,and the results are compared with those obtained by six other surrogate-model-based methods.The results demonstrate that our approach can obtain the maximum net present value(NPV)of the target production optimization problems.

A FLEXIBLE OBJECTIVE-CONSTRAINT APPROACH AND A NEW ALGORITHM FOR CONSTRUCTING THE PARETO FRONT OF MULTIOBJECTIVE OPTIMIZATION PROBLEMS

In this article, a novel scalarization technique, called the improved objective-constraint approach, is introduced to find efficient solutions of a given multiobjective programming problem. The presented scalarized problem extends the objective-constraint problem. It is demonstrated that how adding variables to the scalarized problem, can lead to find conditions for (weakly, properly) Pareto optimal solutions. Applying the obtained necessary and sufficient conditions, two algorithms for generating the Pareto front approximation of bi-objective and three-objective programming problems are designed. These algorithms are easy to implement and can achieve an even approximation of (weakly, properly) Pareto optimal solutions. These algorithms can be generalized for optimization problems with more than three criterion functions, too. The effectiveness and capability of the algorithms are demonstrated in test problems.

Environmental,economic and exergy analysis of separation of ternary azeotrope by variable pressure extractive distillation based on multi-objective optimization

In this work,the ternary azeotrope of tert-butyl alcohol/ethyl acetate/water is separated by extractive distillation(ED)to recover the available constituents and protect the environment.Based on the conductor like shielding model and relative volatility method,ethylene glycol was selected as the extractant in the separation process.In addition,in view of the characteristic that the relative volatility between components changes with pressure,the multi-objective optimization method based on nondominated sorting genetic algorithm II optimizes the pressure and the amount of solvent cooperatively to avoid falling into the optimal local solution.Based on the optimal process parameters,the proposed heat-integrated process can reduce the gas emissions by 29.30%.The heat-integrated ED,further coupled with the pervaporation process,can reduce gas emission by 42.36%and has the highest exergy efficiency of 47.56%.In addition,based on the heat-integrated process,the proposed two heat pump assisted heat-integrated ED processes show good economic and environmental performance.The double heat pump assisted heat-integrated ED can reduce the total annual cost by 28.78%and the gas emissions by 55.83%compared with the basis process,which has a good application prospect.This work provides a feasible approach for the separation of ternary azeotropes.

A hybrid machine learning optimization algorithm for multivariable pore pressure prediction

Pore pressure is essential data in drilling design,and its accurate prediction is necessary to ensure drilling safety and improve drilling efficiency.Traditional methods for predicting pore pressure are limited when forming particular structures and lithology.In this paper,a machine learning algorithm and effective stress theorem are used to establish the transformation model between rock physical parameters and pore pressure.This study collects data from three wells.Well 1 had 881 data sets for model training,and Wells 2 and 3 had 538 and 464 data sets for model testing.In this paper,support vector machine(SVM),random forest(RF),extreme gradient boosting(XGB),and multilayer perceptron(MLP)are selected as the machine learning algorithms for pore pressure modeling.In addition,this paper uses the grey wolf optimization(GWO)algorithm,particle swarm optimization(PSO)algorithm,sparrow search algorithm(SSA),and bat algorithm(BA)to establish a hybrid machine learning optimization algorithm,and proposes an improved grey wolf optimization(IGWO)algorithm.The IGWO-MLP model obtained the minimum root mean square error(RMSE)by using the 5-fold cross-validation method for the training data.For the pore pressure data in Well 2 and Well 3,the coefficients of determination(R^(2))of SVM,RF,XGB,and MLP are 0.9930 and 0.9446,0.9943 and 0.9472,0.9945 and 0.9488,0.9949 and 0.9574.MLP achieves optimal performance on both training and test data,and the MLP model shows a high degree of generalization.It indicates that the IGWO-MLP is an excellent predictor of pore pressure and can be used to predict pore pressure.

Multi-Strategy Assisted Multi-Objective Whale Optimization Algorithm for Feature Selection

In classification problems,datasets often contain a large amount of features,but not all of them are relevant for accurate classification.In fact,irrelevant features may even hinder classification accuracy.Feature selection aims to alleviate this issue by minimizing the number of features in the subset while simultaneously minimizing the classification error rate.Single-objective optimization approaches employ an evaluation function designed as an aggregate function with a parameter,but the results obtained depend on the value of the parameter.To eliminate this parameter’s influence,the problem can be reformulated as a multi-objective optimization problem.The Whale Optimization Algorithm(WOA)is widely used in optimization problems because of its simplicity and easy implementation.In this paper,we propose a multi-strategy assisted multi-objective WOA(MSMOWOA)to address feature selection.To enhance the algorithm’s search ability,we integrate multiple strategies such as Levy flight,Grey Wolf Optimizer,and adaptive mutation into it.Additionally,we utilize an external repository to store non-dominant solution sets and grid technology is used to maintain diversity.Results on fourteen University of California Irvine(UCI)datasets demonstrate that our proposed method effectively removes redundant features and improves classification performance.The source code can be accessed from the website:https://github.com/zc0315/MSMOWOA.

Composition optimization and performance prediction for ultra-stable water-based aerosol based on thermodynamic entropy theory

Water-based aerosol is widely used as an effective strategy in electro-optical countermeasure on the battlefield used to the preponderance of high efficiency,low cost and eco-friendly.Unfortunately,the stability of the water-based aerosol is always unsatisfactory due to the rapid evaporation and sedimentation of the aerosol droplets.Great efforts have been devoted to improve the stability of water-based aerosol by using additives with different composition and proportion.However,the lack of the criterion and principle for screening the effective additives results in excessive experimental time consumption and cost.And the stabilization time of the aerosol is still only 30 min,which could not meet the requirements of the perdurable interference.Herein,to improve the stability of water-based aerosol and optimize the complex formulation efficiently,a theoretical calculation method based on thermodynamic entropy theory is proposed.All the factors that influence the shielding effect,including polyol,stabilizer,propellant,water and cosolvent,are considered within calculation.An ultra-stable water-based aerosol with long duration over 120 min is obtained with the optimal fogging agent composition,providing enough time for fighting the electro-optic weapon.Theoretical design guideline for choosing the additives with high phase transition temperature and low phase transition enthalpy is also proposed,which greatly improves the total entropy change and reduce the absolute entropy change of the aerosol cooling process,and gives rise to an enhanced stability of the water-based aerosol.The theoretical calculation methodology contributes to an abstemious time and space for sieving the water-based aerosol with desirable performance and stability,and provides the powerful guarantee to the homeland security.

Optimization of chemistry and process parameters for control of intermetallic formation in Mg sludges

Intermetallic formation in sludge during magnesium(Mg)melting,holding and high pressure die casting practices is a very important issue.But,very often it is overlooked by academia,original equipment manufacturers(OEM),metal ingot producers and even die casters.The aim of this study was to minimize the intermetallic formation in Mg sludge via the optimization of the chemistry and process parameters.The Al8Mn5 intermetallic particles were identified by the microstructure analysis based on the Al and Mn ratio.The design of experiment(DOE)technique,Taguchi method,was employed to minimize the intermetallic formation in the sludge of Mg alloys with various chemical compositions of Al,Mn,Fe,and different process parameters,holding temperature and holding time.The sludge yield(SY)and intermetallic size(IS)was selected as two responses.The optimum combination of the levels in terms of minimizing the intermetallic formation were 9 wt.%Al,0.15 wt.%Mn,0.001 wt.%(10 ppm)Fe,690℃ for the holding temperature and holding at 30 mins for the holding time,respectively.The best combination for smallest intermetallic size were 9 wt.%Al,0.15 wt.%Mn,0.001 wt.%(10 ppm)Fe,630℃ for the holding temperature and holding at 60 mins for the holding time,respectively.Three groups of sludge factors,Chemical Sludge(CSF),Physical Sludge(PSF)and Comprehensive Sludge Factors(and CPSF)were established for prediction of sludge yields and intermetallic sizes in Al-containing Mg alloys.The CPSF with five independent variables including both chemical elements and process parameters gave high accuracy in prediction,as the prediction of the PSF with only the two processing parameters of the melt holding temperature and time showed a relatively large deviation from the experimental data.The Chemical Sludge Factor was primarily designed for small ingot producers and die casters with a limited melting and holding capacity,of which process parameters could be fixed easily.The Physical Sludge Factor could be used for mass production with a single type of Mg alloy,in which the chemistry fluctuation might be negligible.In large Mg casting suppliers with multiple melting and holding furnaces and a number of Mg alloys in production,the Comprehensive Sludge Factor should be implemented to diminish the sludge formation.