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Data-Driven Design of Epoxy-Granite Machine Foundations: Bayesian Optimization for Enhanced Compressive Strength and

Mohammed Y Abdellah1,2, Osama M Irfan3,4, Hanafy M Omar3

  • 1Mechanical Engineering Department, Faculty of Engineering, Qena University, Qena 83521, Egypt.

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|February 27, 2026
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Summary

This study optimizes epoxy-granite composites for machine tools using data-driven simulations. The developed framework enhances compressive strength and vibration damping, offering a sustainable alternative to cast iron by utilizing granite waste.

Keywords:
Bayesian modelingGaussian Process Regressionepoxygranite compositemechanical propertiesoptimizationsimulation

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Area of Science:

  • Materials Science and Engineering
  • Sustainable Manufacturing
  • Composite Materials

Background:

  • Epoxy-granite (EG) composites offer a sustainable alternative to cast iron for machine tool foundations, utilizing granite quarry waste and epoxy.
  • Enhancing mechanical properties like compressive strength and vibration damping is crucial for machining accuracy and dynamic stability.
  • Existing experimental data has limitations in fully exploring the design space for optimal EG composite formulations.

Purpose of the Study:

  • To develop and validate a data-driven simulation framework for optimizing epoxy-granite composite mechanical properties.
  • To simultaneously maximize compressive strength and vibration damping in EG composites.
  • To assess the reliability and reduce experimental effort in developing high-performance EG composites.

Main Methods:

  • Integration of published experimental data with Gaussian Process Regression (GPR) surrogate modeling.
  • Application of Bayesian optimization (BO) to explore the four-dimensional design space (epoxy content, aggregate fractions).
  • Utilizing Bayesian Weibull analysis for probabilistic reliability assessment.

Main Results:

  • Experimental validation showed compressive strengths up to 76.8 MPa and peak damping ratio of 0.0202.
  • The integrated GPR-BO framework identified optimal formulations (22-26 wt% epoxy, 55-70% fine aggregates) with predicted strengths of 78-85 MPa and damping ratios near 0.022.
  • Bayesian Weibull analysis indicated consistent performance with moderate variability (shape parameters α ≈ 2.4-2.9).

Conclusions:

  • The study presents the first integrated GPR-BO-Bayesian Weibull framework for epoxy-granite composites, enabling simultaneous optimization and reliability assessment.
  • The approach significantly reduces experimental effort (over 70%) and promotes the circular economy by valorizing granite waste.
  • Future experimental validation is recommended to address predictive uncertainties in under-sampled regions.