Multi‐actuated functionally graded piezoelectric micro‐tools design: A multiphysics topology optimization approach

Micro‐tools offer significant promise in a wide range of applications such as cell manipulation, micro‐surgery, and micro/nanotechnology processes. Such special micro‐tools consist of multi‐flexible structures actuated by two or more piezoceramic devices that must generate output displacements and forces at different specified points of the domain and at different directions. The micro‐tool structure acts as a mechanical transformer by amplifying and changing the direction of the piezoceramics output displacements. The design of these micro‐tools involves minimization of the coupling among movements generated by various piezoceramics. To obtain enhanced micro‐tool performance, the concept of multifunctional and functionally graded materials is extended by tailoring elastic and piezoelectric properties of the piezoceramics while simultaneously optimizing the multi‐flexible structural configuration using multiphysics topology optimization. The design process considers the influence of piezoceramic property gradation and also its polarization sign. The method is implemented considering continuum material distribution with special interpolation of fictitious densities in the design domain. As examples, designs of a single piezoactuator, an XY nano‐positioner actuated by two graded piezoceramics, and a micro‐gripper actuated by three graded piezoceramics are considered. The results show that material gradation plays an important role to improve actuator performance, which may also lead to optimal displacements and coupling ratios with reduced amount of piezoelectric material. The present examples are limited to two‐dimensional models because many of the applications for such micro‐tools are planar devices. Copyright © 2008 John Wiley & Sons, Ltd.     

Large strain phase‐field‐based multi‐material topology optimization

A multi‐material topology optimization scheme is presented. The formulation includes an arbitrary number of phases with different mechanical properties. To ensure that the sum of the volume fractions is unity and in order to avoid negative phase fractions, an obstacle potential function, which introduces infinity penalty for negative densities, is utilized. The problem is formulated for nonlinear deformations, and the objective of the optimization is the end displacement. The boundary value problems associated with the optimization problem and the equilibrium equation are solved using the finite element method. To illustrate the possibilities of the method, it is applied to a simple boundary value problem where optimal designs using multiple phases are considered. Copyright © 2015 John Wiley & Sons, Ltd.     

A projection-based method for topology optimization of structures with graded surfaces

Graded surfaces widely exist in natural structures and inspire engineers to apply functionally graded (FG) materials to cover structural surfaces for performance improvement, protection, or other special functionalities. However, how to design such structures with FG surfaces by topology optimization is a quite challenging problem due to the difficulty for determining material properties of structural surfaces with prescribed variation rule. This paper presents a novel projection-based method for topology optimization of this class of FG structures. Firstly, a projection process is proposed for ensuring the material properties of the surfaces vary with a prescribed function. A criterion of determining the values of parameters in projection process is given by a strict theoretical derivation, and then, a new interpolation function is established, which is capable of simultaneously obtaining clear substrate topologies and realizable FG surfaces. Though such structures are actually multimaterial gradient structures, only the design variables of single-material topology optimization problem are needed. In the current research, the classical compliance minimization problem with a mass constraint is considered and the robust formulation is used to control the length scale of substrates. Several 2D and 3D numerical examples illustrate the validity and applicability of the proposed method.     

Multiresolution topology optimization using isogeometric analysis

The paper introduces a novel multiresolution scheme to topology optimization in the framework of the isogeometric analysis. A new variable parameter space is added to implement multiresolution topology optimization based on the Solid Isotropic Material with Penalization approach. Design density variables defined in the variable space are used to approximate the element analysis density by the bivariate B‐spline basis functions, which are easily obtained using k‐refinement strategy in the isogeometric analysis. While the nonuniform rational B‐spline basis functions are used to exactly describe geometric domains and approximate unknown solutions in finite element analysis. By applying a refined sensitivity filter, optimized designs include highly discrete solutions in terms of solid and void materials without using any black and white projection filters. The Method of Moving Asymptotes is used to solve the optimization problem. Various benchmark test problems including plane stress, compliant mechanism inverter, and 2‐dimensional heat conduction are examined to demonstrate the effectiveness and robustness of the present method.     

Semi‐analytical analysis for multi‐directional functionally graded plates: 3‐D elasticity solutions

Semi‐analytical 3‐D elasticity solutions are presented for orthotropic multi‐directional functionally graded plates using the differential quadrature method (DQM) based on the state‐space formalism. Material properties are assumed to vary not only through the thickness but also in the in‐plane directions following an exponential law. The graded in‐plane domain is solved numerically via the DQM, while exact solutions are sought for the thickness domain using the state‐space method. Convergence studies are performed, and the present hybrid semi‐analytical method is validated by comparing numerical results with the exact solutions for a conventional unidirectional functionally graded plate. Finally, effects of material gradient indices on the displacement and stress fields of the plates are investigated and discussed. Copyright © 2009 John Wiley & Sons, Ltd.     

Modelling and process optimization for functionally graded materials

We optimize continuous quench process parameters to produce functionally graded aluminium alloy extrudates. To perform this task, an optimization problem is defined and solved using a standard non‐linear programming algorithm. Ingredients of this algorithm include (1) the process parameters to be optimized, (2) a cost function: the weighted average of the precipitate number density distribution, (3) constraint functions to limit the temperature gradient (and hence distortion and residual stress) and exit temperature, and (4) their sensitivities with respect to the process parameters. The cost and constraint functions are dependent on the temperature and precipitate size which are obtained by balancing energy to determine the temperature distribution and by using a reaction‐rate theory to determine the precipitate particle sizes and their distributions. Both the temperature and the precipitate models are solved via the discontinuous Galerkin finite element method. The energy balance incorporates non‐linear boundary conditions and material properties. The temperature field is then used in the reaction rate model which has as many as 10⁵ degrees‐of‐freedom per finite element node. After computing the temperature and precipitate size distributions we must compute their sensitivities. This seemingly intractable computational task is resolved thanks to the discontinuous Galerkin finite element formulation and the direct differentiation sensitivity method. A three‐dimension example is provided to demonstrate the algorithm. Copyright © 2004 John Wiley & Sons, Ltd.     

Isogeometric topology optimization for continuum structures using density distribution function

This paper will propose a more effective and efficient topology optimization method based on isogeometric analysis, termed as isogeometric topology optimization (ITO), for continuum structures using an enhanced density distribution function (DDF). The construction of the DDF involves two steps. (1)  Smoothness: the Shepard function is firstly utilized to improve the overall smoothness of nodal densities. Each nodal density is assigned to a control point of the geometry. (2) Continuity: the high-order NURBS basis functions are linearly combined with the smoothed nodal densities to construct the DDF for the design domain. The nonnegativity, partition of unity, and restricted bounds [0, 1] of both the Shepard function and NURBS basis functions can guarantee the physical meaning of material densities in the design. A topology optimization formulation to minimize the structural mean compliance is developed based on the DDF and isogeometric analysis to solve structural responses. An integration of the geometry parameterization and numerical analysis can offer the unique benefits for the optimization. Several 2D and 3D numerical examples are performed to demonstrate the effectiveness and efficiency of the proposed ITO method, and the optimized 3D designs are prototyped using the Selective Laser Sintering technique.     

Two‐scale topology optimization in computational material design: An integrated approach

In this work, a new strategy for solving multiscale topology optimization problems is presented. An alternate direction algorithm and a precomputed offline microstructure database (Computational Vademecum) are used to efficiently solve the problem. In addition, the influence of considering manufacturable constraints is examined. Then, the strategy is extended to solve the coupled problem of designing both the macroscopic and microscopic topologies. Full details of the algorithms and numerical examples to validate the methodology are provided.     

Reissner–Mindlin shell implementation and energy conserving isogeometric multi‐patch coupling

A shear‐flexible isogeometric Reissner–Mindlin shell formulation using non‐uniform rational B‐splines basis functions is introduced, which is used for the demonstration of a coupling approach for multiple non‐conforming patches. The six degrees of freedom formulation uses the exact surface normal vectors and curvature. The shell formulation is implemented in an isogeometric analysis framework for computation of structures composed of multiple geometric entities. To enable local model refinement as well as non‐matching domains coupling, a conservative multi‐patch approach using Lagrange multipliers for structured non‐uniform rational B‐splines patches is presented. Here, an additional border frame mesh is used to couple geometries during structural analyses. This frame interface approach avoids the problem of excessive constraints when multiple patches are coupled at one point. First, the shell formulation is verified with several reference cases. Then the influence of the frame interface discretization and frame penalty stiffness on the smoothness of the results is investigated. The effects of the perturbed Lagrangian method in combination with the frame interface approach is shown. In addition, results of models with T‐joint interface connections and perpendicular stiffener patches are presented. Copyright © 2016 John Wiley & Sons, Ltd.     

An approach to multi‐start clustering for global optimization with non‐linear constraints

This paper describes a multi‐start with clustering strategy for use on constrained optimization problems. It is based on the characteristics of non‐linear constrained global optimization problems and extends a strategy previously tested on unconstrained problems. Earlier studies of multi‐start with clustering found in the literature have focused on unconstrained problems with little attention to non‐linear constrained problems. In this study, variations of multi‐start with clustering are considered including a simulated annealing or random search procedure for sampling the design domain and a quadratic programming (QP) sub‐problem used in cluster formation. The strategies are evaluated by solving 18 non‐linear mathematical problems and six engineering design problems. Numerical results show that the solution of a one‐step QP sub‐problem helps predict possible regions of attraction of local minima and can enhance robustness and effectiveness in identifying local minima without sacrificing efficiency. In comparison to other multi‐start techniques found in the literature, the strategies of this study can be attractive in terms of the number of local searches performed, the number of minima found, whether the global minimum is located, and the number of the function evaluations required. Copyright © 2002 John Wiley & Sons, Ltd.     

Higher‐order multi‐resolution topology optimization using the finite cell method

This article presents a detailed study on the potential and limitations of performing higher‐order multi‐resolution topology optimization with the finite cell method. To circumvent stiffness overestimation in high‐contrast topologies, a length‐scale is applied on the solution using filter methods. The relations between stiffness overestimation, the analysis system, and the applied length‐scale are examined, while a high‐resolution topology is maintained. The computational cost associated with nested topology optimization is reduced significantly compared with the use of first‐order finite elements. This reduction is caused by exploiting the decoupling of density and analysis mesh, and by condensing the higher‐order modes out of the stiffness matrix. Copyright © 2016 John Wiley & Sons, Ltd.     

An isogeometric analysis approach to gradient‐dependent plasticity

Gradient‐dependent plasticity can be used to achieve mesh‐objective results upon loss of well‐posedness of the initial/boundary value problem because of the introduction of strain softening, non‐associated flow, and geometric nonlinearity. A prominent class of gradient plasticity models considers a dependence of the yield strength on the Laplacian of the hardening parameter, usually an invariant of the plastic strain tensor. This inclusion causes the consistency condition to become a partial differential equation, in addition to the momentum balance. At the internal moving boundary, one has to impose appropriate boundary conditions on the hardening parameter or, equivalently, on the plastic multiplier. This internal boundary condition can be enforced without tracking the elastic‐plastic boundary by requiring ‐continuity with respect to the plastic multiplier. In this contribution, this continuity has been achieved by using nonuniform rational B‐splines as shape functions both for the plastic multiplier and for the displacements. One advantage of this isogeometric analysis approach is that the displacements can be interpolated one order higher, making it consistent with the interpolation of the plastic multiplier. This is different from previous approaches, which have been exploited. The regularising effect of gradient plasticity is shown for 1‐ and 2‐dimensional boundary value problems.     

Structural topology optimization of vibrating structures with specified eigenfrequencies and eigenmode shapes

In vibration optimization problems, eigenfrequencies are usually maximized in the optimization since resonance phenomena in a mechanical structure must be avoided, and maximizing eigenfrequencies can provide a high probability of dynamic stability. However, vibrating mechanical structures can provide additional useful dynamic functions or performance if desired eigenfrequencies and eigenmode shapes in the structures can be implemented. In this research, we propose a new topology optimization method for designing vibrating structures that targets desired eigenfrequencies and eigenmode shapes. Several numerical examples are presented to confirm that the method presented here can provide optimized vibrating structures applicable to the design of mechanical resonators and actuators. Copyright © 2006 John Wiley & Sons, Ltd.     

An efficient approach for reliability-based topology optimization

This article presents an efficient approach for reliability-based topology optimization (RBTO) in which the computational effort involved in solving the RBTO problem is equivalent to that of solving a deterministic topology optimization (DTO) problem. The methodology presented is built upon the bidirectional evolutionary structural optimization (BESO) method used for solving the deterministic optimization problem. The proposed method is suitable for linear elastic problems with independent and normally distributed loads, subjected to deflection and reliability constraints. The linear relationship between the deflection and stiffness matrices along with the principle of superposition are exploited to handle reliability constraints to develop an efficient algorithm for solving RBTO problems. Four example problems with various random variables and single or multiple applied loads are presented to demonstrate the applicability of the proposed approach in solving RBTO problems. The major contribution of this article comes from the improved efficiency of the proposed algorithm when measured in terms of the computational effort involved in the finite element analysis runs required to compute the optimum solution. For the examples presented with a single applied load, it is shown that the CPU time required in computing the optimum solution for the RBTO problem is 15–30% less than the time required to solve the DTO problems. The improved computational efficiency allows for incorporation of reliability considerations in topology optimization without an increase in the computational time needed to solve the DTO problem.     

Geometrically non‐linear thermoelastic analysis of functionally graded shells using finite element method

A finite element formulation governing the geometrically non‐linear thermoelastic behaviour of plates and shells made of functionally graded materials is derived in this paper using the updated Lagrangian approach. Derivation of the formulation is based on rewriting the Green–Lagrange strain as well as the 2nd Piola–Kirchhoff stress as two second‐order functions in terms of a through‐the‐thickness parameter. Material properties are assumed to vary through the thickness according to the commonly used power law distribution of the volume fraction of the constituents. Within a non‐linear finite element analysis framework, the main focus of the paper is the proposal of a formulation to account for non‐linear stress distribution in FG plates and shells, particularly, near the inner and outer surfaces for small and large values of the grading index parameter. The non‐linear heat transfer equation is also solved for thermal distribution through the thickness by the Rayleigh–Ritz method. Advantages of the proposed approach are assessed and comparisons with available solutions are presented. Copyright © 2007 John Wiley & Sons, Ltd.     

Voigt–Reuss topology optimization for structures with nonlinear material behaviors

This work is directed toward optimizing concept designs of structures featuring inelastic material behaviours by using topology optimization. In the proposed framework, alternative structural designs are described with the aid of spatial distributions of volume fraction design variables throughout a prescribed design domain. Since two or more materials are permitted to simultaneously occupy local regions of the design domain, small-strain integration algorithms for general two-material mixtures of solids are developed for the Voigt (isostrain) and Reuss (isostress) assumptions, and hybrid combinations thereof. Structural topology optimization problems involving non-linear material behaviours are formulated and algorithms for incremental topology design sensitivity analysis (DSA) of energy type functionals are presented. The consistency between the structural topology design formulation and the developed sensitivity analysis algorithms is established on three small structural topology problems separately involving linear elastic materials, elastoplastic materials, and viscoelastic materials. The good performance of the proposed framework is demonstrated by solving two topology optimization problems to maximize the limit strength of elastoplastic structures. It is demonstrated through the second example that structures optimized for maximal strength can be significantly different than those optimized for minimal elastic compliance. © 1997 John Wiley & Sons, Ltd.     

A dual algorithm for the topology optimization of non‐linear elastic structures

Dual algorithms are ideally suited for the purpose of topology optimization since they work in the space of Lagrange multipliers associated with the constraints. To date, dual algorithms have been applied only for linear structures. Here we extend this methodology to the case of non‐linear structures. The perimeter constraint is used to make the topology problem well‐posed. We show that the proposed algorithm yields a value of perimeter that is close to that specified by the user. We also address the issue of manufacturability of these designs, by proposing a variant of the standard dual algorithm, which generates designs that are two‐dimensional although the loading and the geometry are three‐dimensional. Copyright © 2008 John Wiley & Sons, Ltd.     

A material based model for topology optimization of thermoelastic structures

This paper presents the development of a computational model for the topology optimization problem, using a material distribution approach, of a 2-D linear-elastic solid subjected to thermal loads, with a compliance objective function and an isoperimetric constraint on volume. Defining formally the augmented Lagrangian associated with the optimization problem, the optimality conditions are derived analytically. The results of analysis are implemented in a computer code to produce numerical solutions for the optimal topology, considering the temperature distribution independent of design. The design optimization problem is solved via a sequence of linearized subproblems. The computational model developed is tested in example problems. The influence of both the temperature and the finite element model on the optimal solution obtained is analysed.     

空隙、杂质及组分突变对功能梯度构件动力特性的影响

功能梯度材料具有复杂的细部结构, 其内部构造远比匀质材料复杂, 因此其构件动力分析很难求得其解析解。本文中提出了一种新颖的功能梯度构件动力分析的细观元法, 其目的在于建立材料的宏观性能与其组分材料性能及细观构造之间的定量关系, 以便揭示不同的材料组合及其变异所具有不同的宏观性能的内在机制。利用细观元法对含有空隙、 杂质及组分突变等情况下的功能梯度构件进行动力分析, 求得其三维固有频率及振型的三维分布。从而可知空隙、 杂质及组分突变均对功能梯度材料构件的宏观动力特性有很大的影响。