SHAPE SENSITIVITY ANALYSIS FOR STEADY METAL-FORMING PROCESSES

This paper develops a numerical technique for determining the shape sensitivity parameters in steady metal- forming processes such as drawing and rolling. The adjoint method is applied to the discrete non-linear system of equations in the finite element model in order to determine the discrete matrix of sensitivity parameters. In this work, two specific cases are considered. The first case involves determining the sensitivity of the process power requirement to the process geometry and the second case involves determining the sensitivity of the internal state variable distribution in the final product to the process geometry. The process geometry is assumed to be characterized by a finite number of shape parameters. The internal state variable distribution in this case represents the resistance to plastic flow and is considered to be related to the quality of the final product. Numerical examples for a simple drawing process are presented to demonstrate the efficiency of the algorithm.     

声场-结构耦合系统灵敏度分析及优化设计研究

给出了低频声－结构耦合系统的有限元方程，并在此基础上提出声一结构耦合系统的包含尺寸和形状设计变量的优化设计模型，建立基于灵敏度分析求解的优化设计方法，重点推导了耦合系统的特征频率和声压级响应关于设计变量的灵敏度方程。在JIFEX软件中实现上述理论和算法，并通过灵敏度比较和优化设计的数值算例，进一步说明该研究方法对声结构耦合系统的工程设计具有实用意义。     

拱坝体形优化中的三维解析敏度

本文针对基于有限元分析的拱坝体形优化，采用改进的半解析法进行三维敏度分析。推导了敏度分析有关公式，并研制了相应的程序。敏度验证和拱坝优化算例表明，本文方法精度高、数值稳定，对基于三维有限元分析的拱坝体形优化是有效的。     

结构优化设计中的灵敏度分析

阐述了灵敏度分析在带有频率约束的结构优化设计中的重要性，并且指出主模态局部化与非经典系统的灵敏性是结构设计师需要研究的课题。     

A TWO-LEVEL DECOMPOSITION METHOD FOR SHAPE OPTIMIZATION OF STRUCTURES

The paper proposes a two-level decomposition method for shape optimization of structures. The optimization problem is divided into two subproblems on the basis of the different effects on structural behaviour of different kinds of design variables. A minimum mass subproblem is solved to determine the sizing variables and a constraint evaluation function based on norm optimization is minimized to determine the shape variables. An efficient coupling technique is used between the subproblems to ensure very rapid and steady convergence. Numerical results are presented to demonstrate the effectiveness of the method. © 1997 by John Wiley & Sons, Ltd.     

基于分层设计变量的复合材料层合板优化设计及灵敏度分析

在复合材料层合板的结构优化设计中,提出分层设计变量的优化方法以满足实际工程需要。在结构位移、自振频率和屈曲临界荷载灵敏度分析中,给出了刚度矩阵对分层厚度和分层角度设计变量的灵敏度计算公式,考虑了分层厚度变化引起层合板对称中心的改变,保证了计算准确性。数值算例验证了灵敏度算法的精度,应用实例显示了分层设计变量方法的实用性。     

SENSITIVITY ANALYSIS AND OPTIMIZATION OF ELASTIC-PLASTIC STRUCTURES

Elastic-plastic analysis problems formulated as quadratic programming problems involve energy functional and equilibrium and yield constraints that depend on the design, material and loading. In this paper we consider the problem of determining the variation of structural response with respect to variations of these parameters. A general result for discrete structures is presented and implications for optimal design are discussed.     

复合材料层合板屈曲稳定性优化设计及其灵敏度计算方法

笔者在有限元分析基础上研究了以屈曲稳定性作为约束条件或优化目标的复合材料层合板结构优化设计及其灵敏度分析方法,重点讨论了屈曲临界荷载灵敏度对内力场和载荷的依赖关系及其在铺层优化、尺寸优化和形状优化问题中的不同计算方法,并在JIFEX软件中实现了复杂结构复合材料层合板优化设计方法。数值算例验证了本文算法和程序的有效性。     

SHAPE DESIGN SENSITIVITY FROM PARTIAL DIFFERENTIAL EQUATION TO IMPLEMENTATION

The paper uses a distributed parameter approach to evaluate the shape design sensitivities of various types of structures such as elastic beams, plates, arches and shells. Sensitivities of sialic response are determined and consideration is given to computational aspects of the implementation of the methods.     

OPTIMAL DESIGN FOR NON-STEADY-STATE METAL FORMING PROCESSES—I. SHAPE OPTIMIZATION METHOD

We suggest a shape optimization method for a non-linear and non-steady-state metal forming problem. It consists in optimizing the initial shape of the part as well as the shape of the preform tool during a two-step forging operation, for which the shape of the second operation is known. Shapes are described using spline functions and optimal parameter values of the splines are searched in order to produce, at the end of the forging sequence, a part with a prescribed geometric accuracy, optimal metallurgical properties and for a minimal production cost. The finite element method, including numerous remeshing operations, is used for the simulation of the process. We suggest using a least-squares-type algorithm for the unconstrained optimization method (based on external penalty) for which we describe the calculation of the derivatives of the objective function. We show that it can reduce to calculations which are equivalent to the derivative calculations of steady-state processes and to evolution equations. Therefore, the computational cost of such an optimization is quite reasonable, even for complex forging processes. Lastly, in order to reduce the errors due to the numerous remeshings during the simulation, we introduce error estimation and adaptive remeshing methods with respect to the calculation of derivatives.     

OPTIMAL DESIGN FOR NON-STEADY-STATE METAL FORMING PROCESSES—II. APPLICATION OF SHAPE OPTIMIZATION IN FORGING

This paper is the second part of a two-part article about shape optimization of metal forming processes. This part is focused on numerical applications of the optimization method which has been described in the first paper. The main feature of this work is the analytical calculations of the derivatives of the objective function for a non-linear, non-steady-state problem with large deformations. The calculations are based on the differentiation of the discrete objective function and on the differentiation of the discrete equations of the forging problem. Our aim here is to show the feasibility and the efficiency of such a method with numerical examples. We recall the formulation and the resolution of the direct problem of hot axisymmetrical forging. Then, a first type of shape optimization problem is considered: the optimization of the shape of the initial part for a one-step forging operation. Two academic problems allow for checking the accuracy of the analytical derivatives, and for studying the convergence rate of the optimization procedure. Both constrained and unconstrained problems are considered. Afterwards, a second type of inverse problem of design is considered: the shape optimization of the preforming tool, for a two-step forging process. A satisfactory shape is obtained after few iterations of the optimization procedure.     

结构静力问题的重特征值灵敏度分析

静力学中的结构设计，模型修正和优化等问题都属于矩阵逆特征值问题，解决这类问题的关键是求出特征值和特征向量关于设计参数的灵敏度，本文基于多元函数论和代数反问题理论，得到了具有重特征值情形的结构灵敏度解的形式，并给出了相应的计算实例。     

基于扩展等几何分析和混沌离子运动算法的带孔结构形状优化设计

为了解决带孔结构形状优化问题,提出了一种将扩展等几何分析方法和混沌离子运动算法相结合的优化求解模式。针对带孔结构的力学计算,采用扩展等几何分析方法,以几何体外轮廓划分背景网格,利用非均匀有理B样条描述带孔边界,其中在劲度矩阵组装过程中,孔内区域不做积分。另外,为获得高精度的积分计算,与孔边界相关的单元采用自适应四叉树细化规则。在优化模型中,以描述结构形状的控制点作为设计变量,以结构质量最小作为优化目标;利用离子运动优化算法代替传统的敏感性移动渐进法对优化模型进行求解。带孔无限平板算例的扩展等几何分析计算结果和转矩臂结构优化算例的计算结果证明了本文方法的有效性。     

SHAPE OPTIMIZATION AND MINIMUM WEIGHT LIMIT DESIGN OF ARCHES

The paper is concerned with the optimization of arches, using classical beam finite elements, for the minimum elastic displacements and the minimum weight designs under ultimate loading conditions.

The concept of separate but dependent design spaces for node coordinates and member plastic capacities is introduced. The shape optimization problem, whereby a norm of the elastic displacement vector is minimized, is formulated in the space of node coordinate variables. Then the minimum weight limit design problem in the space of member plastic capacities is considered using the static theorem of limit analysis. An iterative procedure alternating these two approaches is presented in the paper. The nonlinear unconstrained optimization and linear programming techniques are used to solve the corresponding numerical problems. The proposed method is illustrated by numerical examples.     

COMPARATIVE EVALUATION OF DIFFERENT OPTIMIZATION ALGORITHMS FOR STRUCTURAL DESIGN APPLICATIONS

Non-linear programming algorithms play an important role in structural design optimization. Fortunately, several algorithms with computer codes are available. At NASA Lewis Research Centre, a project was initiated to assess the performance of eight different optimizers through the development of a computer code CometBoards. This paper summarizes the conclusions of that research. CometBoards was employed to solve sets of small, medium and large structural problems, using the eight different optimizers on a Cray-YMP8E/8128 computer. The reliability and efficiency of the optimizers were determined from the performance of these problems. For small problems, the performance of most of the optimizers could be considered adequate. For large problems, however, three optimizers (two sequential quadratic programming routines, DNCONG of IMSL and SQP of IDESIGN, along with Sequential Unconstrained Minimizations Technique SUMT) outperformed others. At optimum, most optimizers captured an identical number of active displacement and frequency constraints but the number of active stress constraints differed among the optimizers. This discrepancy can be attributed to singularity conditions in the optimization and the alleviation of this discrepancy can improve the efficiency of optimizers.     

A SHAPE AND SIZE OPTIMIZATION ALGORITHM FOR MACHINE TOOL ELEMENT DESIGN

A shape and size optimization algorithm is developed to incorporate the shape and size variables in a recently developed machine tool simulation and design methodology known as Integrated Machining Process Design Simulator (IMPDS). This shape optimization algorithm, using coordinates of master nodes, parameters of geometric equations, coordinate linking and symmetry option approaches presents a general and flexible way of controlling and optimizing the structural shape of machine tool elements. An application of the proposed shape and size optimization algorithm indicates that the shape and size parameters have significant effects on the structural characteristics and the dynamic behavior of machine tool elements.     

考虑作动器联接方式的结构形状控制优化

以压电材料梁式作动器控制复合材料层合板形状的设计问题为对象,研究有限个独立控制参数条件下的形状最优控制问题。研究了作动器与信号发生器(独立控制参数)联接关系的参数化描述方式,建立了作动器联接方式与控制参数协同设计的问题提法;针对优化问题中离散变量(联接方式描述参数)和连续变量(控制参数)共存的特点,建立了遗传算法和线性最小二乘(Linear Least Square,LLS)方法相结合的求解策略和方法;在响应分析所采用的有限元模型中,采用粘结层单元描述本体结构与作动器之间的连接。复合材料层合板形状控制设计的实例,验证了该文中建立的问题提法、优化模型和求解策略的有效性。     

结构可靠性灵敏度分析的低偏差抽样方法

由于蒙特卡罗(MC)方法具有程序结构简单,收敛速度与问题维数无关等优点,故其在结构可靠性及可靠性灵敏度分析中得到了广泛应用。但是计算效率低这一主要缺点限制了该方法的应用范围。通过引进单位超立方体中不同的低偏差点集代替伪随机数序列,并结合重要抽样技术建立了结构可靠性灵敏度分析的低偏差抽样方法。该方法不但可以大幅度减少抽样点数目,还能够得到确定性的估计值避免传统MC方法只能得到概率意义下误差的缺陷。通过数值算例可以看出该方法具有较高的计算精度和效率。     

SENSITIVITY ANALYSIS AND A MIXED APPROACH TO THE OPTIMIZATION OF SYMMETRIC LAYERED COMPOSITE PLATES

This paper studies the sensitivity analysis of the static structural compliance of symmetric layered composite plates with respect to the fiber orientation in terms of continuous and finite element discretized formulations. From the optimality criterion obtained based on the sensitivity analysis, it is found that the number of different angles of the fibers in an optimal plate is no more than 4 under rather general conditions. Making use of the sensitivity information and optimality criterion approach, we construct a mixed method for adjusting the fiber orientations to minimize the structural compliance of composite plates. Furthermore, the non-convcxity of compliances of composite plates is shown by numerical experiment.     

PREFORM DIE SHAPE DESIGN IN METAL FORMING USING AN OPTIMIZATION METHOD

An optimization algorithm for preform die shape design in metal-forming processes is developed in this paper. The preform die shapes are represented by cubic B-spline curves. The control points of the B-spline are used as the design variables. The optimization objective is to reduce the difference between the realized and desired final forging shapes. The sensitivities of the objective function with respect to the design variables are developed in detail. The numerical examples show that the optimization method and the sensitivity analysis developed in this paper are very useful and the design results are satisfactory. Importantly, the preform die shapes designed by this method are easily manufacturable and can be implemented in practical metal-forming operations. This optimization method and the sensitivity analysis can also be applied in the preform design of complex industrial metal-forming problems. © 1997 by John Wiley & Sons, Ltd.