Non-parametric free-form optimization method for frame structures

In this paper, we propose a parameter-free shape optimization method based on the variational method for designing the smooth optimal free-form of a spatial frame structure. A stiffness design problem where the compliance is minimized under a volume constraint is solved as an example of shape design problems of frame structures. The optimum design problem is formulated as a distributed-parameter shape optimization problem under the assumptions that each member is varied in the out-of-plane direction to the centroidal axis and that the cross section is prismatic. The shape gradient function and the optimality conditions are then theoretically derived. The optimal curvature distribution is determined by applying the derived shape gradient function to each member as a fictitious distributed force both to vary the member in the optimum direction and to minimize the objective functional without shape parametrization, while maintaining the members’ smoothness. The validity and practical utility of this method were verified through several design examples. It was confirmed that axial-force-carrying structures were obtained by this method.     

Parameter-free optimum design method of stiffeners on thin-walled structures

In this paper, we present a shape optimization method for designing stiffeners on thin-walled or shell structures. Solutions are proposed to deal with a stiffness maximization problem and a volume minimization problem, which are subject to a volume constraint and a compliance constraint, respectively. The boundary shapes of the stiffeners are determined under a condition where the stiffeners are movable in the in-plane direction to the surface. Both problems are formulated as distributed-parameter shape optimization problems, and the shape gradient functions are derived using a material derivative method and an adjoint variable method. The optimal free-boundary shapes of the stiffeners are obtained by applying the derived shape gradient function to the $H^{1}$ gradient method for shells, which is a parameter-free shape optimization method proposed by one of the authors. Several stiffener design examples are presented to validate the proposed method and demonstrate its practical utility.     

An integrated approach for shape and topology optimization of shell structures

In this paper an automated approach for simultaneous shape and topology optimization of shell structures is presented. Most research in the last decades considered these optimization techniques separately, seeking an initial optimal material layout and refining the shape of the solution later. The method developed in this work combines both optimization techniques, where the shape of the shell structure and material distribution are optimized simultaneously, with the aim of finding the optimum design that maximizes the stiffness of the shell. This formulation involves a variable ground structure for topology optimization, since the shape of the shell is modified in the course of the process. The method has been implemented into a computational model and the feasibility of the approach is demonstrated using several examples.     

Combined shape and reinforcement layout optimization of shell structures

This paper presents a combined shape and reinforcement layout optimization method of shell structures. The approach described in this work is applied to optimize simultaneously the geometry of the shell mid-plane as well as the layout of surface stiffeners on the shell. This formulation involves a variable ground structure, since the shape of the shell surface is modified in the course of the process. Here we shall consider a global structural design criterion, namely the compliance of the structure, following basically the classical problem of distributing a limited amount of material in the most favourable way.The solution to the problem is based on a finite element discretization of the design domain. The material within each of the elements is modelled by a second-rank layered Mindlin plate microstructure. By a simple modification, this type of microstructure can be used to find the optimum distribution of stiffeners on shell structures. The effective stiffness properties are computed analytically through a smear-out procedure. The proposed method has been implemented into a general optimization software called Odessy and satisfactorily applied to the solution of some numerical examples, which are illustrated at the end of the paper.     

The optimum shape of cooling towers

Numerous computer optimization techniques have been developed and applied primarily to the design of structures composed of discrete elements. Continuous surface structures have been optimized primarily by methods based upon the differential or integral calculus (e.g. the calculus of variations). However, the determination of the optimal shape of continuous surface structures can also be approached by algebraic methods more suitable for digital computation. If the coordinates of the middle surface of a shell are expressed by a finite polynomial series, an optimization problem in a finite set of discrete variables results. In the present work, this method is applied to a particular example of a shell of revolution: a natural draft cooling tower. A simple preliminary design model is formulated in order to evaluate the potential savings due to numerical optimization, and the resulting nonlinear programming problem is solved by iterated linear programming. The results indicate that the method is feasible and that significant savings might be attainable by computerized shape optimization.     

On simultaneous shape and material layout optimization of shell structures

This work presents a computational method for integrated shape and topology optimization of shell structures. Most research in the last decades considered both optimization techniques separately, seeking an initial optimal topology and refining the shape of the solution later. The method implemented in this work uses a combined approach, were the shape of the shell structure and material distribution are optimized simultaneously. This formulation involves a variable ground structure for topology optimization, since the shape of the shell mid-plane is modified in the course of the process. It was considered a simple type of design problem, where the optimization goal is to minimize the compliance with respect to the variables that control the shape, material fraction and orientation, subjected to a constraint on the total volume of material. The topology design problem has been formulated introducing a second rank layered microestructure, where material properties are computed by a “smear-out” procedure. The method has been implemented into a general optimization software called ODESSY, developed at the Institute of Mechanical Engineering in Aalborg. The computational model was tested in several numerical applications to illustrate and validate the approach.     

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.     

Shape optimization of satellite tanks for minimum weight and maximum storage capacity

The aim of structural design is to determine the dimensions and the shape of a system that fulfils certain requirements in an optimal way. Although this problem is not at all new, the application of mathematical algorithms together with multicriteria and shape optimization techniques as strategies for achieving an optimum are still very rarely used in practice. The efficiency of the optimization procedure SAPOP is demonstrated through the shape optimization of ultra light shell structures (e.g. satellite tanks) for which bending effects as well as the influence of large deformations in the shell theory are taken into account. After establishing a corresponding transfer matrix method for analysis, the meridional shape can be determined by using special shape functions (modified ellipsoids) and a direct shape optimization strategy. In addition, simultaneous optimization of shape and wall thickness distribution is introduced.Presented and pre-accepted at the IUTAM Symposium on Structural Optimization in Melbourne, Feb. 1988     

Constrained multifidelity optimization using model calibration

Multifidelity optimization approaches seek to bring higher-fidelity analyses earlier into the design process by using performance estimates from lower-fidelity models to accelerate convergence towards the optimum of a high-fidelity design problem. Current multifidelity optimization methods generally fall into two broad categories: provably convergent methods that use either the high-fidelity gradient or a high-fidelity pattern-search, and heuristic model calibration approaches, such as interpolating high-fidelity data or adding a Kriging error model to a lower-fidelity function. This paper presents a multifidelity optimization method that bridges these two ideas; our method iteratively calibrates lower-fidelity information to the high-fidelity function in order to find an optimum of the high-fidelity design problem. The algorithm developed minimizes a high-fidelity objective function subject to a high-fidelity constraint and other simple constraints. The algorithm never computes the gradient of a high-fidelity function; however, it achieves first-order optimality using sensitivity information from the calibrated low-fidelity models, which are constructed to have negligible error in a neighborhood around the solution. The method is demonstrated for aerodynamic shape optimization and shows at least an 80% reduction in the number of high-fidelity analyses compared other single-fidelity derivative-free and sequential quadratic programming methods. The method uses approximately the same number of high-fidelity analyses as a multifidelity trust-region algorithm that estimates the high-fidelity gradient using finite differences.     

Shape Optimization by Free-Form Deformation: Existence Results and Numerical Solution for Stokes Flows

Shape optimization problems governed by PDEs result from many applications in computational fluid dynamics. These problems usually entail very large computational costs and require also a suitable approach for representing and deforming efficiently the shape of the underlying geometry, as well as for computing the shape gradient of the cost functional to be minimized. Several approaches based on the displacement of a set of control points have been developed in the last decades, such as the so-called free-form deformations. In this paper we present a new theoretical result which allows to recast free-form deformations into the general class of perturbation of identity maps, and to guarantee the compactness of the set of admissible shapes. Moreover, we address both a general optimization framework based on the continuous shape gradient and a numerical procedure for solving efficiently three-dimensional optimal design problems. This framework is applied to the optimal design of immersed bodies in Stokes flows, for which we consider the numerical solution of a benchmark case study from literature.     

Simultaneous shape and topology optimization of shell structures

In this research, Method of Moving Asymptotes (MMA) is utilized for simultaneous shape and topology optimization of shell structures. It is shown that this approach is well matched with the large number of topology and shape design variables. The currently practiced technology for optimization is to find the topology first and then to refine the shape of structure. In this paper, the design parameters of shape and topology are optimized simultaneously in one go. In order to model and control the shape of free form shells, the NURBS (Non Uniform Rational B-Spline) technology is used. The optimization problem is considered as the minimization of mean compliance with the total material volume as active constraint and taking the shape and topology parameters as design variables. The material model employed for topology optimization is assumed to be the Solid Isotropic Material with Penalization (SIMP). Since the MMA optimization method requires derivatives of the objective function and the volume constraint with respect to the design variables, a sensitivity analysis is performed. Also, for alleviation of the instabilities such as mesh dependency and checkerboarding the convolution noise cleaning technique is employed. Finally, few examples taken from literature are presented to demonstrate the performance of the method and to study the effect of the proposed concurrent approach on the optimal design in comparison to the sequential topology and shape optimization methods.     

Discrete variable optimization of plate structures using dual methods

This study presents an efficient method for optimum design of plate and shell structures, when the design variables are continuous or discrete. Both sizing and shape design variables are considered. First the structural responses, such as element forces, are approximated in terms of some intermediate variables. By substituting these approximate relations into the original design problem, an explicit nonlinear approximate design task with high quality approximation is achieved. This problem with continuous variables can be solved very efficiently by means of numerical optimization techniques, the results of which are then used for discrete variable optimization. Now, the approximate problem is converted into a sequence of second level approximation problems of separable form, each of which is solved by a dual strategy with discrete design variables. The approach is efficient in terms of the number of required structural analyses, as well as the overall computational cost of optimization. Examples are offered and compared with other methods to demonstrate the features of the proposed method.     

Optimal topology design of structures under dynamic loads

When elastic structures are subjected to dynamic loads, a propagation problem is considered to predict structural transient response. To achieve better dynamic performance, it is important to establish an optimum structural design method. Previous work focused on minimizing the structural weight subject to dynamic constraints on displacement, stress, frequency, and member size. Even though these methods made it possible to obtain the optimal size and shape of a structure, it is necessary to obtain an optimal topology for a truly optimal design. In this paper, the homogenization design method is utilized to generate the optimal topology for structures and an explicit direct integration scheme is employed to solve the linear transient problems. The optimization problem is formulated to find the best configuration of structures that minimizes the dynamic compliance within a specified time interval. Examples demonstrate that the homogenization design method can be extended to the optimal topology design method of structures under impact loads.Presented at WCSMO-2, held in Zakopane, Poland, 1997     

A systematic topology optimization approach for optimal stiffener design

A systematic topology optimization based approach is proposed to design the optimal stiffener of three-dimensional shell/plate structures for static and eigenvalue problems. Optimal stiffener design involves the determination of the best location and orientation. In this paper, the stiffener location problem is solved by a microstructure-based design domain method and the orientation problem is modelled as an optimization orientation problem of equivalent orthotropic materials, which is solved by a newly developed energy-based method. Examples are presented to demonstrate the application of the proposed approach.     

Geometric parameter optimization in multi-axis machining

This paper presents a systematic method for the determination of optimal geometric machining parameters in multi-axis machining. Machining accuracy is considered to be determined by a set of geometric parameters: the design parameters of the cutter, the positioning of the cutter, the orientation of the cutter etc. First, we formulate the general nonlinear constrained optimization model of the machining process. The optimal machining result is expected to produce the least deviation between the designed surface and the actual surface. This objective is accomplished by minimizing the deviation between the designed surface and the actual surface during machining. The details of how to characterize and calculate the deviation is then discussed for both ruled surface milling and general free-form surface milling. The swept surface is developed based on robotic manipulation and is used to model the actual surface. A signed distance function is constructed to perform the comparison which returns the signed distance from each sampled point to the designed surface. The direct search algorithm (Nelder-Mead simplex algorithm and pattern search algorithm in this paper) is used to solve our optimization problems due to possible discontinuity of the objective function and large nonlinearity of the problem. Three numerical examples and necessary comparisons are given to demonstrate the effectiveness of our method. The first example shows the generation of the swept volume of a filled-end cutter. The second example employs the swept surface generation method to solve a parameter optimization problem. Sensitivity analysis is performed for the parameters critical to machining accuracy. The third example optimizes the cutter orientation relative to the part surface to minimize the kinematics error caused by kinematics transformation and interpolation of multi-axis machines.     

Minimum cost design of a welded orthogonally stiffened cylindrical shell

In this study the optimal design of a cylindrical orthogonally stiffened shell member of an offshore fixed platform truss, loaded by axial compression and external pressure, is investigated. Ring stiffeners of welded box section and stringers of halved rolled I-section are used. The design variables considered in the optimization are the shell thickness as well as the dimensions and numbers of stiffeners. The design constraints relate to the shell, panel ring and panel stringer buckling, as well as manufacturing limitations. The cost function includes the cost of material, forming of plate elements into cylindrical shape, welding and painting. In the optimization a number of relatively new mathematical optimization methods (leap-frog - LFOPC, Dynamic-Q, ETOPC, and particle swarm - PSO) are used, in order to ensure confidence that the finally computed optimum design is accurately determined, and indeed corresponds to a global minimum. The continuous optimization procedures are adapted to allow for discrete values of the design variables to be used in the final manufacturing of the truss member. A comparison of the computed optimum costs of the stiffened and un-stiffened assemblies, shows that significant cost savings can be achieved by orthogonal stiffening, since the latter allows for considerable reduction of the shell thickness, which results in large material and manufacturing cost savings.     

Parametric free-form shape design with PDE models and reduced basis method

We present a coupling of the reduced basis methods and free-form deformations for shape optimization and design of systems modelled by elliptic PDEs. The free-form deformations give a parameterization of the shape that is independent of the mesh, the initial geometry, and the underlying PDE model. The resulting parametric PDEs are solved by reduced basis methods. An important role in our implementation is played by the recently proposed empirical interpolation method, which allows approximating the non-affinely parameterized deformations with affinely parameterized ones. These ingredients together give rise to an efficient online computational procedure for a repeated evaluation design environment like the one for shape optimization. The proposed approach is demonstrated on an airfoil inverse design problem.     

Optimum design of composite shells subject to natural frequency constraints

A technique for the optimum (minimum weight) design of a composite shell subject to constraints on its natural frequencies is presented. The optimization problem is posed as a general mathematical programming problem in which one or more of the inequality constraints involves the shell natural frequencies, which must be evaluated numerically during the optimization. For this reason, a method for numerically evaluating the natural frequencies of composite shells is also presented. The method is based upon the finite element method of structural analysis and Rayleigh's principle. Because the element used is applicable to anisotropic shells of arbitrary shape, the method is very general. By using Rayleigh's principle, the necessity of assembling overall mass and stiffness matrices for the shell is eliminated. The optimization is performed by nondimensionalizing the mathematical programming problem and using the penalty function method of Fiacco and McCormick to transform the problem to a sequence of unconstrained minimizations having solutions which converge to the solution of the original (constrained) problem. The unconstrained minimizations are performed using the variable metric method of Fletcher and Powell. Derivatives of the nondimensional frequency constraints are evaluated numerically using difference equations. The frequency calculation method is demonstrated by calculating the fundamental frequency for the transverse vibration mode of a multilayered cylindrical shell with fixed overall geometry and variable composite geometry. Results indicate that the frequency increases with increasing fiber orientation angle, fiber volume fraction, or lamina thickness. The optimization technique is demonstrated by minimizing the weight of the shell discussed above subject to a constraint on its fundamental transverse frequency. The design variables are the fiber orientation angle, the fiber volume fraction, and the lamina thickness. Results are presented and explained in terms of the physical aspects of the problem.     

Developable polynomial surface approximation to smooth surfaces for fabrication parameters of a large curved shell plate by Differential Evolution

This paper presents a simple and efficient method to approximate a developable surface to a compound design surface by a polynomial. It is required to predict a final shape of roll bending in the fabrication of a curved shell plate. The roll bending process usually makes the cylindrical or conical curvature from an initial flat plate. It means that the final shape is developable or the surface representation has zero Gaussian curvature. The fabrication shape is important in order to estimate process parameters of roller bending.An optimization problem is formulated to determine the polynomial surface which is in the closest proximity to the design surface or the given shell plate, which is subjected to developability. The results and the efficiency of this algorithm are verified and evaluated by applying it to some shell plates which are obtained from a real ship model. The predicted bending shape becomes fundamental information in determining more process parameters for the fabrication of a compound curved shell plate.