Topology optimization study of arterial bypass configurations using the level set method

We studied the arterial bypass design problem using a level set based topology optimization method. The blood flow in the artery was considered as the non-Newtonian flow governed by the Navier–Stokes equations coupled with the modified Cross model for the shear dependent viscosity. The fluid–solid interface is immersed in the design domain by the level set method and the fictitious porous material method. The sensitivity velocity derived by the level set based continuous adjoint method was utilized to control the evolution of the level set function. In order to accommodate the irregular analysis domains, the flow equations and the level set equations were computed on two different unstructured grids respectively. Three idealized arterial bypass configurations problems with the minimum flow shear stress objective were studied in the numerical examples. The results indicated that the optimal arterial bypass designs can effectively reduce integral of the squared shear rate in the artery and have a superior performance for the arterial grafting.     

Topology optimization using a reaction–diffusion equation

This paper presents a structural topology optimization method based on a reaction–diffusion equation. In our approach, the design sensitivity for the topology optimization is directly employed as the reaction term of the reaction–diffusion equation. The distribution of material properties in the design domain is interpolated as the density field which is the solution of the reaction–diffusion equation, so free generation of new holes is allowed without the use of the topological gradient method. Our proposed method is intuitive and its implementation is simple compared with optimization methods using the level set method or phase field model. The evolution of the density field is based on the implicit finite element method. As numerical examples, compliance minimization problems of cantilever beams and force maximization problems of magnetic actuators are presented to demonstrate the method’s effectiveness and utility.     

Topology optimization of multi-material negative Poisson’s ratio metamaterials using a reconciled level set method

Metamaterials are defined as a family of rationally designed artificial materials which can provide extraordinary effective properties compared with their nature counterparts. This paper proposes a level set based method for topology optimization of both single and multiple-material Negative Poisson’s Ratio (NPR) metamaterials. For multi-material topology optimization, the conventional level set method is advanced with a new approach exploiting the reconciled level set (RLS) method. The proposed method simplifies the multi-material topology optimization by evolving each individual material with a single level set function and reconciling the result level set field with the Merriman–Bence–Osher (MBO) operator. The NPR metamaterial design problem is recast as a variational problem, where the effective elastic properties of the spatially periodic microstructure are formulated as the strain energy functionals under uniform displacement boundary conditions. The adjoint variable method is utilized to derive the shape sensitivities by combining the general linear elastic equation with a weak imposition of Dirichlet boundary conditions. The design velocity field is constructed using the steepest descent method and integrated with the level set method. Both single and multiple-material mechanical metamaterials are achieved in 2D and 3D with different Poisson’s ratios and volumes. Benchmark designs are fabricated with multi-material 3D printing at high resolution. The effective auxetic properties of the achieved designs are verified through finite element simulations and characterized using experimental tests as well.     

A topological derivative method for topology optimization

We propose a fictitious domain method for topology optimization in which a level set of the topological derivative field for the cost function identifies the boundary of the optimal design. We describe a fixed-point iteration scheme that implements this optimality criterion subject to a volumetric resource constraint. A smooth and consistent projection of the region bounded by the level set onto the fictitious analysis domain simplifies the response analysis and enhances the convergence of the optimization algorithm. Moreover, the projection supports the reintroduction of solid material in void regions, a critical requirement for robust topology optimization. We present several numerical examples that demonstrate compliance minimization of fixed-volume, linearly elastic structures.     

Topology optimization of shell structures using adaptive inner-front (AIF) level set method

A new topology optimization using adaptive inner-front level set method is presented. In the conventional level set-based topology optimization, the optimum topology strongly depends on the initial level set due to the incapability of inner-front creation during the optimization process. In the present work, in this regard, an algorithm for inner-front creation is proposed in which the sizes, the positions, and the number of new inner-fronts during the optimization process can be globally and consistently identified. In the algorithm, the criterion of inner-front creation for compliance minimization problems of linear elastic structures is chosen as the strain energy density along with volumetric constraint. To facilitate the inner-front creation process, the inner-front creation map is constructed and used to define new level set function. In the implementation of inner-front creation algorithm, to suppress the numerical oscillation of solutions due to the sharp edges in the level set function, domain regularization is carried out by solving the edge smoothing partial differential equation (smoothing PDE). To update the level set function during the optimization process, the least-squares finite element method (LSFEM) is adopted. Through the LSFEM, a symmetric positive definite system matrix is constructed, and non-diffused and non-oscillatory solution for the hyperbolic PDE such as level set equation can be obtained. As applications, three-dimensional topology optimization of shell structures is treated. From the numerical examples, it is shown that the present method brings in much needed flexibility in topologies during the level set-based topology optimization process.     

A level set method for structural shape and topology optimization using radial basis functions

This paper presents an alternative level set method for shape and topology optimization of continuum structures. An implicit free boundary representation model is established by embedding structural boundary into the zero level set of a higher-dimensional level set function. An explicit parameterization scheme for the level set surface is proposed by using radial basis functions with compact support. In doing so, the originally more difficult shape and topology optimization, driven by the temporal and spatial Hamilton–Jacobi partial differential equation (PDE), is transformed into a relatively easier size optimization of the expansion coefficients of the basis functions. The design optimization is converted to an iterative numerical process that combines the parameterization with a derivation of the shape sensitivity of the design functions, so as to allow using mathematical programming algorithms to solve the level set-based design problem and avoid directly solving the Hamilton–Jacobi PDE. Furthermore, a numerically more stable and efficient volume integration scheme is proposed to implement calculations of the shape derivatives, leading to the creation of new holes which are generated initially along the boundary and then propagated to the interior of the design domain. Two widely studied examples are used to demonstrate the effectiveness of the proposed optimization method.     

基于反应扩散方程的水平集结构拓扑优化方法与实现

为实现更加先进的拓扑优化算法,研究采用反应扩散方程的水平集结构拓扑优化方法,通过理论推导给出算法中的参数选择建议.该方法允许在拓扑优化过程中生成新的孔洞,初始结构无须包含孔洞,不需要重新初始化步骤,从而可提高算法的收敛性.针对传统拓扑优化中主要采用体积约束、以柔度最小为目标和体积保留率设定存在一定主观性的问题,探究不同体积保留率下的结构应力水平的变化规律,结果显示可以依据结构最大应力水平与体积保留率的变化规律确定最优体积保留率.     

A level set approach for optimal design of smart energy harvesters

The proliferation of Micro-Electro-Mechanical Systems (MEMS), portable electronics and wireless sensing networks has raised the need for a new class of devices with self-powering capabilities. Vibration-based piezoelectric energy harvesters provide a very promising solution, as a result of their capability of converting mechanical energy into electrical energy through the direct piezoelectric effect. However, the identification of fast, accurate methods and rational criteria for the design of piezoelectric energy harvesting devices still poses a challenge. In this work, a level set-based topology optimization approach is proposed to synthesize mechanical energy harvesting devices for self-powered micro systems. The energy harvester design problem is reformulated as a variational problem based on the concept of topology optimization, where the optimal geometry is sought by maximizing the energy conversion efficiency of the device. To ensure computational efficiency, the shape gradient of the energy conversion efficiency is analytically derived using the material time derivative approach and the adjoint variable method. A design velocity field is then constructed using the steepest descent method, which is further integrated into level set methods. The reconciled level set (RLS) method is employed to solve multi-material shape and topology optimization problems, using the Merriman–Bence–Osher (MBO) operator. Designs with both single and multiple materials are presented, which constitute improvements with respect to existing energy harvesting designs.     

Structure topology optimization: fully coupled level set method via FEMLAB

This paper presents a procedure which can easily implement the 2D compliance minimization structure topology optimization by the level set method using the FEMLAB package. Instead of a finite difference solver for the level set equation, as is usually the case, a finite element solver for the reaction–diffusion equation is used to evolve the material boundaries. All of the optimization procedures are implemented in a user-friendly manner. A FEMLAB code can be downloaded from the homepage www.imtek.de/simulation and is free for educational purposes.     

A level-set method for steady-state and transient natural convection problems

This paper introduces a topology optimization method for 2D and 3D, steady-state and transient heat transfer problems that are dominated by natural convection in the fluid phase and diffusion in the solid phase. The geometry of the fluid-solid interface is described by an explicit level set method which allows for both shape and topological changes in the optimization process. The heat transfer in the fluid is modeled by an advection-diffusion equation. The fluid velocity is described by the incompressible Navier-Stokes equations augmented by a Boussinesq approximation of the buoyancy forces. The temperature field in the solid is predicted by a linear diffusion model. The governing equations in both the fluid and solid phases are discretized in space by a generalized formulation of the extended finite element method which preserves the crisp geometry definition of the level set method. The interface conditions at the fluid-solid boundary are enforced by Nitsche’s method. The proposed method is studied for problems optimizing the geometry of cooling devices. The numerical results demonstrate the applicability of the proposed method for a wide spectrum of problems. As the flow may exhibit dynamic instabilities, transient phenomena need to be considered when optimizing the geometry. However, the computational burden increases significantly when the time evolution of the flow fields needs to be resolved.     

Topology optimization of steady Navier-Stokes flow via a piecewise constant level set method

This paper presents a piecewise constant level set method for the topology optimization of steady Navier-Stokes flow. Combining piecewise constant level set functions and artificial friction force, the optimization problem is formulated and analyzed based on a design variable. The topology sensitivities are computed by the adjoint method based on Lagrangian multipliers. In the optimization procedure, the piecewise constant level set function is updated by a new descent method, without the needing to solve the Hamilton-Jacobi equation. To achieve optimization, the piecewise constant level set method does not track the boundaries between the different materials but instead through the regional division, which can easily create small holes without topological derivatives. Furthermore, we make some attempts to avoid updating the Lagrangian multipliers and to deal with the constraints easily. The algorithm is very simple to implement, and it is possible to obtain the optimal solution by iterating a few steps. Several numerical examples for both two- and three-dimensional problems are provided, to demonstrate the validity and efficiency of the proposed method.     

Simultaneous optimization of the material properties and the topology of functionally graded structures

A level set based method is proposed for the simultaneous optimization of the material properties and the topology of functionally graded structures. The objective of the present study is to determine the optimal material properties (via the material volume fractions) and the structural topology to maximize the performance of the structure in a given application. In the proposed method, the volume fraction and the structural boundary are considered as the design variables, with the former being discretized as a scalar field and the latter being implicitly represented by the level set method. To perform simultaneous optimization, the two design variables are integrated into a common objective functional. Sensitivity analysis is conducted to obtain the descent directions. The optimization process is then expressed as the solution to a coupled Hamilton-Jacobi equation and diffusion partial differential equation. Numerical results are provided for the problem of mean compliance optimization in two dimensions.     

The parameterized level set method for structural topology optimization with shape sensitivity constraint factor

In recent years, the parameterized level set method (PLSM) has attracted widespread attention for its good stability, high efficiency and the smooth result of topology optimization compared with the conventional level set method. In the PLSM, the radial basis functions (RBFs) are often used to perform interpolation fitting for the conventional level set equation, thereby transforming the iteratively updating partial differential equation (PDE) into ordinary differential equations (ODEs). Hence, the RBFs play a key role in improving efficiency, accuracy and stability of the numerical computation in the PLSM for structural topology optimization, which can describe the structural topology and its change in the optimization process. In particular, the compactly supported radial basis function (CS-RBF) has been widely used in the PLSM for structural topology optimization because it enjoys considerable advantages. In this work, based on the CS-RBF, we propose a PLSM for structural topology optimization by adding the shape sensitivity constraint factor to control the step length in the iterations while updating the design variables with the method of moving asymptote (MMA). With the shape sensitivity constraint factor, the updating step length is changeable and controllable in the iterative process of MMA algorithm so as to increase the optimization speed. Therefore, the efficiency and stability of structural topology optimization can be improved by this method. The feasibility and effectiveness of this method are demonstrated by several typical numerical examples involving topology optimization of single-material and multi-material structures.

     

Shape feature control in structural topology optimization

A variational approach to shape feature control in topology optimization is presented in this paper. The method is based on a new class of surface energies known as higher-order energies as opposed to the conventional energies for problem regularization, which are linear. In employing a quadratic energy functional in the objective of the topology optimization, non-trivial interactions between different points on the structural boundary are introduced, thus favoring a family of shapes with strip-like (or beam) features. In addition, the quadratic energy functional can be seamlessly integrated into the level set framework that represents the geometry of the structure implicitly. The shape gradient of the quadratic energy functional is fully derived in the paper, and it is incorporated in the level set approach for topology optimization. The approach is demonstrated with benchmark examples of structure optimization and compliant mechanism design. The results presented show that this method is capable of generating strip-like (or beam) designs with specified feature width, which have highly desirable characteristics and practical benefits and uniquely distinguish the proposed method.     

A new level set method for systematic design of hinge-free compliant mechanisms

This paper presents a new level set-based method to realize shape and topology optimization of hinge-free compliant mechanisms. A quadratic energy functional used in image processing applications is introduced in the level set method to control the geometric width of structural components in the created mechanism. A semi-implicit scheme with an additive operator splitting (AOS) algorithm is employed to solve the Hamilton-Jacobi partial differential equation (PDE) in the level set method. The design of compliant mechanisms is mathematically represented as a general non-linear programming with a new objective function augmented by the high-order energy term. The structural optimization is thus changed to a numerical process that describes the design as a sequence of motions by updating the implicit boundaries until the optimized structure is achieved under specified constraints. In doing so, it is expected that numerical difficulties such as the Courant-Friedrichs-Lewy (CFL) condition and periodically applied re-initialization procedures in most conventional level set methods can be eliminated. In addition, new holes can be created inside the design domain. The final mechanism configurations consist of strip-like members suitable for generating distributed compliance, and solving the de-facto hinge problem in the design of compliant mechanisms. Two widely studied numerical examples are studied to demonstrate the effectiveness of the proposed method in the context of designing distributed compliant mechanisms.     

A topology optimization approach using VOF method

Topology optimization methods with continuous design variables obtained by the homogenization formula or the solid isotropic microstructure with penalty (SIMP) model are widely used in the layout of structures. In the implementation of these approaches, one must take into account several issues, e.g., irregularity of the problem, occurrence of the checkerboard pattern, and intermediate density. To suppress these phenomena, the employment of additional strategies such as the perimeter control or the filtering method will be required. In this paper, a topology optimization method which can eliminate these difficulties is developed based on the volume of fluid (VOF) method. In the method, shape design is described in terms of the VOF function. Since this function is defined by a volume fraction of material occupying each element, it can be recognized as a continuous material density in the SIMP model. Within the framework of the VOF analysis, the topology optimization procedure is reduced to a convection motion of the material density governed by a Hamilton–Jacobi equation as in the level set method. Through numerical examples, the validity of the proposed method is investigated.     

Design of distributed compliant micromechanisms with an implicit free boundary representation

In this paper, a parameterization approach is presented for structural shape and topology optimization of compliant mechanisms using a moving boundary representation. A level set model is developed to implicitly describe the structural boundary by embedding into a scalar function of higher dimension as zero level set. The compactly supported radial basis function of favorable smoothness and accuracy is used to interpolate the level set function. Thus, the temporal and spatial initial value problem is now converted into a time-separable parameterization problem. Accordingly, the more difficult shape and topology optimization of the Hamilton–Jacobi equation is then transferred into a relatively easy size optimization with the expansion coefficients as design variables. The design boundary is therefore advanced by applying the optimality criteria method to iteratively evaluate the size optimization so as to update the level set function in accordance with expansion coefficients of the interpolation. The optimization problem of the compliant mechanism is established by including both the mechanical efficiency as the objective function and the prescribed material usage as the constraint. The design sensitivity analysis is performed by utilizing the shape derivative. It is noted that the present method is not only capable of simultaneously addressing shape fidelity and topology changes with a smooth structural boundary but also able to avoid some of the unfavorable numerical issues such as the Courant–Friedrich–Levy condition, the velocity extension algorithm, and the reinitialization procedure in the conventional level set method. In particular, the present method can generate new holes inside the material domain, which makes the final design less insensitive to the initial guess. The compliant inverter is applied to demonstrate the availability of the present method in the framework of the implicit free boundary representation.     

Explicit level set and density methods for topology optimization with equivalent minimum length scale constraints

The goal of this paper is to introduce local length scale control in an explicit level set method for topology optimization. The level set function is parametrized explicitly by filtering a set of nodal optimization variables. The extended finite element method (XFEM) is used to represent the non-conforming material interface on a fixed mesh of the design domain. In this framework, a minimum length scale is imposed by adopting geometric constraints that have been recently proposed for density-based topology optimization with projections filters. Besides providing local length scale control, the advantages of the modified constraints are twofold. First, the constraints provide a computationally inexpensive solution for the instabilities which often appear in level set XFEM topology optimization. Second, utilizing the same geometric constraints in both the density-based topology optimization and the level set optimization enables to perform a more unbiased comparison between both methods. These different features are illustrated in a number of well-known benchmark problems for topology optimization.

     

Constrained isogeometric design optimization of lattice structures on curved surfaces: computation of design velocity field

This paper presents an immersed boundary approach for level set topology optimization considering stress constraints. A constraint agglomeration technique is used to combine the local stress constraints into one global constraint. The structural response is predicted by the eXtended Finite Element Method. A Heaviside enrichment strategy is used to model strong and weak discontinuities with great ease of implementation. This work focuses on low-order finite elements, which given their simplicity are the most popular choice of interpolation for topology optimization problems. The predicted stresses strongly depend on the intersection configuration of the elements and are prone to significant errors. Robust computation of stresses, regardless of the interface position, is essential for reliable stress constraint prediction and sensitivities. This study adopts a recently proposed fictitious domain approach for penalization of displacement gradients across element faces surrounding the material interface. In addition, a novel XFEM informed stabilization scheme is proposed for robust computation of stresses. Through numerical studies the penalized spatial gradients combined with the stabilization scheme is shown to improve prediction of stresses along the material interface. The proposed approach is applied to the benchmark topology optimization problem of an L-shaped beam in two and three dimensions using material-void and material-material problem setups. Linear and hyperelastic materials are considered. The stress constraints are shown to be efficient in eliminating regions with high stress concentration in all scenarios considered.     

A level-set-based topology and shape optimization method for continuum structure under geometric constraints

Recent advances in level-set-based shape and topology optimization rely on free-form implicit representations to support boundary deformations and topological changes. In practice, a continuum structure is usually designed to meet parametric shape optimization, which is formulated directly in terms of meaningful geometric design variables, but usually does not support free-form boundary and topological changes. In order to solve the disadvantage of traditional step-type structural optimization, a unified optimization method which can fulfill the structural topology, shape, and sizing optimization at the same time is presented. The unified structural optimization model is described by a parameterized level set function that applies compactly supported radial basis functions (CS-RBFs) with favorable smoothness and accuracy for interpolation. The expansion coefficients of the interpolation function are treated as the design variables, which reflect the structural performance impacts of the topology, shape, and geometric constraints. Accordingly, the original topological shape optimization problem under geometric constraint is fully transformed into a simple parameter optimization problem; in other words, the optimization contains the expansion coefficients of the interpolation function in terms of limited design variables. This parameterization transforms the difficult shape and topology optimization problems with geometric constraints into a relatively straightforward parameterized problem to which many gradient-based optimization techniques can be applied. More specifically, the extended finite element method (XFEM) is adopted to improve the accuracy of boundary resolution. At last, combined with the optimality criteria method, several numerical examples are presented to demonstrate the applicability and potential of the presented method.