An enhanced genetic algorithm for structural topology optimization

Genetic algorithms (GAs) have become a popular optimization tool for many areas of research and topology optimization an effective design tool for obtaining efficient and lighter structures. In this paper, a versatile, robust and enhanced GA is proposed for structural topology optimization by using problem‐specific knowledge. The original discrete black‐and‐white (0–1) problem is directly solved by using a bit‐array representation method. To address the related pronounced connectivity issue effectively, the four‐neighbourhood connectivity is used to suppress the occurrence of checkerboard patterns. A simpler version of the perimeter control approach is developed to obtain a well‐posed problem and the total number of hinges of each individual is explicitly penalized to achieve a hinge‐free design. To handle the problem of representation degeneracy effectively, a recessive gene technique is applied to viable topologies while unusable topologies are penalized in a hierarchical manner. An efficient FEM‐based function evaluation method is developed to reduce the computational cost. A dynamic penalty method is presented for the GA to convert the constrained optimization problem into an unconstrained problem without the possible degeneracy. With all these enhancements and appropriate choice of the GA operators, the present GA can achieve significant improvements in evolving into near‐optimum solutions and viable topologies with checkerboard free, mesh independent and hinge‐free characteristics. Numerical results show that the present GA can be more efficient and robust than the conventional GAs in solving the structural topology optimization problems of minimum compliance design, minimum weight design and optimal compliant mechanisms design. It is suggested that the present enhanced GA using problem‐specific knowledge can be a powerful global search tool for structural topology optimization. Copyright © 2005 John Wiley & Sons, Ltd.     

Using the sequential linear integer programming method as a post‐processor for stress‐constrained topology optimization problems

This paper deals with topology optimization of load‐carrying structures defined on discretized continuum design domains. In particular, the minimum compliance problem with stress constraints is considered. The finite element method is used to discretize the design domain into n finite elements and the design of a certain structure is represented by an n‐dimensional binary design variable vector. In order to solve the problems, the binary constraints on the design variables are initially relaxed and the problems are solved with both the method of moving asymptotes and the sparse non‐linear optimizer solvers for continuous optimization in order to compare the two solvers. By solving a sequence of problems with a sequentially lower limit on the amount of grey allowed, designs that are close to ‘black‐and‐white’ are obtained. In order to get locally optimal solutions that are purely {0, 1}ⁿ, a sequential linear integer programming method is applied as a post‐processor. Numerical results are presented for some different test problems. Copyright © 2008 John Wiley & Sons, Ltd.     

A Multi‐Objective Design Approach for the c Chart Considering Taguchi Loss Function

The present paper proposes a multi‐objective design approach for the c chart, considering in the optimization process of the chart parameters both the statistical and the economic objectives. In particular, the minimization of the hourly total quality related costs is the considered objective to carry out the economic goal, whereas the statistical objective is reached by the minimization the out‐of‐control average run length of the chart. A mixed integer non‐linear constrained mathematical model is formulated to solve the treated multi‐objective optimization problem, whereas the Pareto optimal frontier is described by the ε‐constraint method. In order to show the employment of the proposed approach, an illustrative example is developed and the related considerations are given. Finally, some sensitivity analysis is also performed to investigate the effects of operative and costs parameters on the chart performance. Copyright © 2013 John Wiley & Sons, Ltd.     

Shape optimization using a NURBS‐based interface‐enriched generalized FEM

This study presents a gradient‐based shape optimization over a fixed mesh using a non‐uniform rational B‐splines‐based interface‐enriched generalized finite element method, applicable to multi‐material structures. In the proposed method, non‐uniform rational B‐splines are used to parameterize the design geometry precisely and compactly by a small number of design variables. An analytical shape sensitivity analysis is developed to compute derivatives of the objective and constraint functions with respect to the design variables. Subtle but important new terms involve the sensitivity of shape functions and their spatial derivatives. Verification and illustrative problems are solved to demonstrate the precision and capability of the method. Copyright © 2016 John Wiley & Sons, Ltd.     

An adaptive non‐conforming finite‐element method for Reissner–Mindlin plates

Adaptive algorithms are important tools for efficient finite‐element mesh design. In this paper, an error controlled adaptive mesh‐refining algorithm is proposed for a non‐conforming low‐order finite‐element method for the Reissner–Mindlin plate model. The algorithm is controlled by a reliable and efficient residual‐based a posteriori error estimate, which is robust with respect to the plate's thickness. Numerical evidence for this and the efficiency of the new algorithm is provided in the sense that non‐optimal convergence rates are optimally improved in our numerical experiments. Copyright © 2003 John Wiley & Sons, Ltd.     

Numerical methods for the topology optimization of structures that exhibit snap‐through

The inclusion of non‐linear elastic analyses into the topology optimization problem is necessary to capture the finite deformation response, e.g. the geometric non‐linear response of compliant mechanisms. In previous work, the non‐linear response is computed by standard non‐linear elastic finite element analysis. Here, we incorporate a load–displacement constraint method to traverse non‐linear equilibrium paths with limit points to design structures that exhibit snap‐through behaviour. To accomplish this, we modify the basic arc length algorithm and embed this analysis into the topology optimization problem. Copyright © 2002 John Wiley & Sons, Ltd.     

A consistent grayscale‐free topology optimization method using the level‐set method and zero‐level boundary tracking mesh

This paper proposes a level‐set based topology optimization method incorporating a boundary tracking mesh generating method and nonlinear programming. Because the boundary tracking mesh is always conformed to the structural boundary, good approximation to the boundary is maintained during optimization; therefore, structural design problems are solved completely without grayscale material. Previously, we introduced the boundary tracking mesh generating method into level‐set based topology optimization and updated the design variables by solving the level‐set equation. In order to adapt our previous method to general structural optimization frameworks, the incorporation of the method with nonlinear programming is investigated in this paper. To successfully incorporate nonlinear programming, the optimization problem is regularized using a double‐well potential. Furthermore, the sensitivities with respect to the design variables are strictly derived to maintain consistency in mathematical programming. We expect the investigation to open up a new class of grayscale‐free topology optimization. The usefulness of the proposed method is demonstrated using several numerical examples targeting two‐dimensional compliant mechanism and metallic waveguide design problems. Copyright © 2014 John Wiley & Sons, Ltd.     

Topology optimization of fluid problems using genetic algorithm assisted by the Kriging model

A non‐gradient‐based approach for topology optimization using a genetic algorithm is proposed in this paper. The genetic algorithm used in this paper is assisted by the Kriging surrogate model to reduce computational cost required for function evaluation. To validate the non‐gradient‐based topology optimization method in flow problems, this research focuses on two single‐objective optimization problems, where the objective functions are to minimize pressure loss and to maximize heat transfer of flow channels, and one multi‐objective optimization problem, which combines earlier two single‐objective optimization problems. The shape of flow channels is represented by the level set function. The pressure loss and the heat transfer performance of the channels are evaluated by the Building‐Cube Method code, which is a Cartesian‐mesh CFD solver. The proposed method resulted in an agreement with previous study in the single‐objective problems in its topology and achieved global exploration of non‐dominated solutions in the multi‐objective problems. © 2016 The Authors International Journal for Numerical Methods in Engineering Published by John Wiley & Sons Ltd     

Topology optimization using non‐conforming finite elements: three‐dimensional case

As in the case of two‐dimensional topology design optimization, numerical instability problems similar to the formation of two‐dimensional checkerboard patterns occur if the standard eight‐node conforming brick element is used. Motivated by the recent success of the two‐dimensional non‐conforming elements in completely eliminating checkerboard patterns, we aim at investigating the performance of three‐dimensional non‐conforming elements in controlling the patterns that are estimated overly stiff by the brick elements. To this end, we will investigate how accurately the non‐conforming elements estimate the stiffness of the patterns. The stiffness estimation is based on the homogenization method by assuming the periodicity of the patterns. To verify the superior performance of the elements, we consider three‐dimensional compliance minimization and compliant mechanism design problems and compare the results by the non‐conforming element and the standard 8‐node conforming brick element. Copyright © 2005 John Wiley & Sons, Ltd.     

Bilateral filtering for structural topology optimization

Filtering has been a major approach used in the homogenization‐based methods for structural topology optimization to suppress the checkerboard pattern and relieve the numerical instabilities. In this paper a bilateral filtering technique originally developed in image processing is presented as an efficient approach to regularizing the topology optimization problem. A non‐linear bilateral filtering process leads to a suitable problem regularization to eliminate the checkerboard instability, pronounced edge preserving smoothing characteristics to favour the 0–1 convergence of the mass distribution, and computational efficiency due to its single pass and non‐iterative nature. Thus, we show that the application of the bilateral filtering brings more desirable effects of checkerboard‐free, mesh independence, crisp boundary, computational efficiency and conceptual simplicity. The proposed bilateral technique has a close relationship with the conventional domain filtering and range filtering. The proposed method is implemented in the framework of a power‐law approach based on the optimality criteria and illustrated with 2D examples of minimum compliance design that has been extensively studied in the recent literature of topology optimization and its efficiency and accuracy are highlighted. Copyright © 2005 John Wiley & Sons, Ltd.     

An efficient numerical method for computing the topological sensitivity of arbitrary‐shaped features in plate bending

The objective of this paper is to introduce an efficient numerical scheme to compute the topological sensitivity (TS) of arbitrary‐shaped features in plate bending. The proposed method captures the first‐order change in quantities of interest (example: plate compliance) when an arbitrary‐shaped feature is created within a plate. Both the theory and algorithms are provided to rapidly compute the feature‐specific TS for the classic Kirchhoff–Love plate models. An important application of the proposed method is in design exploration/optimization wherein a designer can explore the impact of including plate features, without recourse to repeated finite element analysis. The proposed method is illustrated and validated through numerical experiments. Copyright © 2009 John Wiley & Sons, Ltd.     

Effective volume‐fraction optimization for thermal stress reduction in FGMs using irregular h‐refinement

The volume fraction of constituent particles in functionally graded materials (FGM) varies continuously and functionally, and its optimal tailoring could be made by the numerical optimization incorporated with the finite element method. In such a case, the mesh density in finite element discretization of the volume fraction field influences the final design quality such that the further objective function reduction requires the refinement of volume fraction meshes. However, the uniform refinement of the volume fraction mesh is not effective, from the numerical point of view, particularly when the finite difference scheme is employed. This numerical inefficiency could be resolved by locally increasing the mesh density only where more volume‐fraction flexibility (i.e. more mesh density) is required. In this paper, we propose an effective volume‐fraction optimization procedure by applying the irregular h‐refinement to the volume fraction discretization. Copyright © 2003 John Wiley & Sons, Ltd.     

胶印机滚筒结构的拓扑及尺寸优化设计

胶印机滚筒在印刷压力作用下的挠曲变形是影响印品质量的重要原因。以PZ1740胶印机橡皮滚筒为研究对象,提出了一种基于拓扑优化和尺寸优化的橡皮滚筒结构设计方法。建立了滚筒结构的二维拓扑模型,以应变能最小为目标,体积分数作为约束,得到滚筒结构的拓扑分布;在拓扑构型基础上,建立了滚筒结构的参数化模型,以挠曲变形最小为目标,结构质量作为约束条件进行尺寸优化,得到了滚筒具体的结构。优化分析结果表明,优化后的滚筒结构在质量约束的条件下有效地减小了挠曲变形,提出的方法在胶印机滚筒结构优化设计中可行且有效。     

A human‐like numerical technique for design of engineering systems

Because of the necessity for considering various creative and engineering design criteria, optimal design of an engineering system results in a highly‐constrained multi‐objective optimization problem. Major numerical approaches to such optimal design are to force the problem into a single objective function by introducing unjustifiable additional parameters and solve it using a single‐objective optimization method. Due to its difference from human design in process, the resulting design often becomes completely different from that by a human designer. This paper presents a novel numerical design approach, which resembles the human design process. Similar to the human design process, the approach consists of two steps: (1) search for the solution space of the highly‐constrained multi‐objective optimization problem and (2) derivation of a final design solution from the solution space. Multi‐objective gradient‐based method with Lagrangian multipliers (MOGM‐LM) and centre‐of‐gravity method (CoGM) are further proposed as numerical methods for each step. The proposed approach was first applied to problems with test functions where the exact solutions are known, and results demonstrate that the proposed approach can find robust solutions, which cannot be found by conventional numerical design approaches. The approach was then applied to two practical design problems. Successful design in both the examples concludes that the proposed approach can be used for various design problems that involve both the creative and engineering design criteria. Copyright © 2005 John Wiley & Sons, Ltd.     

Topology optimization of creeping fluid flows using a Darcy–Stokes finite element

A new methodology is proposed for the topology optimization of fluid in Stokes flow. The binary design variable and no‐slip condition along the solid–fluid interface are regularized to allow for the use of continuous mathematical programming techniques. The regularization is achieved by treating the solid phase of the topology as a porous medium with flow governed by Darcy's law. Fluid flow throughout the design domain is then expressed as a single system of equations created by combining and scaling the Stokes and Darcy equations. The mixed formulation of the new Darcy–Stokes system is solved numerically using existing stabilized finite element methods for the individual flow problems. Convergence to the no‐slip condition is demonstrated by assigning a low permeability to solid phase and results suggest that auxiliary boundary conditions along the solid–fluid interface are not needed. The optimization objective considered is to minimize dissipated power and the technique is used to solve examples previously examined in literature. The advantages of the Darcy–Stokes approach include that it uses existing stabilization techniques to solve the finite element problem, it produces 0–1 (void–solid) topologies (i.e. there are no regions of artificial material), and that it can potentially be used to optimize the layout of a microscopically porous material. Copyright © 2005 John Wiley & Sons, Ltd.     

Continuum structural topological optimizations with stress constraints based on an active constraint technique

Stress‐related problems have not been given the same attention as the minimum compliance topological optimization problem in the literature. Continuum structural topological optimization with stress constraints is of wide engineering application prospect, in which there still are many problems to solve, such as the stress concentration, an equivalent approximate optimization model and etc. A new and effective topological optimization method of continuum structures with the stress constraints and the objective function being the structural volume has been presented in this paper. To solve the stress concentration issue, an approximate stress gradient evaluation for any element is introduced, and a total aggregation normalized stress gradient constraint is constructed for the optimized structure under the r?th load case. To obtain stable convergent series solutions and enhance the control on the stress level, two p‐norm global stress constraint functions with different indexes are adopted, and some weighting p‐norm global stress constraint functions are introduced for any load case. And an equivalent topological optimization model with reduced stress constraints is constructed,being incorporated with the rational approximation for material properties, an active constraint technique, a trust region scheme, and an effective local stress approach like the qp approach to resolve the stress singularity phenomenon. Hence, a set of stress quadratic explicit approximations are constructed, based on stress sensitivities and the method of moving asymptotes. A set of algorithm for the one level optimization problem with artificial variables and many possible non‐active design variables is proposed by adopting an inequality constrained nonlinear programming method with simple trust regions, based on the primal‐dual theory, in which the non‐smooth expressions of the design variable solutions are reformulated as smoothing functions of the Lagrange multipliers by using a novel smoothing function. Finally, a two‐level optimization design scheme with active constraint technique, i.e. varied constraint limits, is proposed to deal with the aggregation constraints that always are of loose constraint (non active constraint) features in the conventional structural optimization method. A novel structural topological optimization method with stress constraints and its algorithm are formed, and examples are provided to demonstrate that the proposed method is feasible and very effective. © 2016 The Authors. International Journal for Numerical Methods in Engineering published by John Wiley & Sons Ltd.     

On the equivalence of optimality criterion and sequential approximate optimization methods in the classical topology layout problem

We study the ‘classical’ topology optimization problem, in which minimum compliance is sought, subject to linear constraints. Using a dual statement, we propose two separable and strictly convex subproblems for use in sequential approximate optimization (SAO) algorithms. Respectively, the subproblems use reciprocal and exponential intermediate variables in approximating the non‐linear compliance objective function. Any number of linear constraints (or linearly approximated constraints) are provided for. The relationships between the primal variables and the dual variables are found in analytical form. For the special case when only a single linear constraint on volume is present, we note that application of the ever‐popular optimality criterion (OC) method to the topology optimization problem, combined with arbitrary values for the heuristic numerical damping factor η proposed by Bendsøe, results in an updating scheme for the design variables that is identical to the application of a rudimentary dual SAO algorithm, in which the subproblems are based on exponential intermediate variables. What is more, we show that the popular choice for the damping factor η=0.5 is identical to the use of SAO with reciprocal intervening variables. Finally, computational experiments reveal that subproblems based on exponential intervening variables result in improved efficiency and accuracy, when compared to SAO subproblems based on reciprocal intermediate variables (and hence, the heuristic topology OC method hitherto used). This is attributed to the fact that a different exponent is computed for each design variable in the two‐point exponential approximation we have used, using gradient information at the previously visited point. Copyright © 2007 John Wiley & Sons, Ltd.     

Topology design of reactive mufflers for enhancing their acoustic attenuation performance and flow characteristics simultaneously

When seeking to enhance the acoustic attenuation performance of a reactive muffler, it is necessary to ensure that the flow resistance does not increase significantly. To date, there have been very few attempts to simultaneously optimize the transmission loss and pressure drop of a muffler. In this study, a multiobjective topology optimization problem is formulated to maximize the transmission loss at a target frequency and minimize the pressure drop simultaneously. The objective function in the formulation is given as the sum of weighted transmission loss and weighted pressure drop. The effect of the weighting factors on the optimal topologies of a muffler is investigated. Furthermore, the physical interpretation of partition layouts of optimized mufflers is discussed. The proposed muffler design method involving multiobjective topology optimization is compared with the previous muffler design method that involves single‐objective topology optimization to maximize only the transmission loss. The most important advantage of this study is shown by considering numerical results; the proposed muffler design method is applicable to nonconcentric expansion chamber mufflers, unlike the previous muffler design method. Copyright © 2012 John Wiley & Sons, Ltd.     

Topology synthesis of large‐displacement compliant mechanisms

This paper describes the use of topology optimization as a synthesis tool for the design of large‐displacement compliant mechanisms. An objective function for the synthesis of large‐displacement mechanisms is proposed together with a formulation for synthesis of path‐generating compliant mechanisms. The responses of the compliant mechanisms are modelled using a total Lagrangian finite element formulation, the sensitivity analysis is performed using the adjoint method and the optimization problem is solved using the method of moving asymptotes. Procedures to circumvent some numerical problems are discussed. Copyright © 2001 John Wiley & Sons, Ltd.