Shape optimization of axisymmetric preform tools in forging using a direct differentiation method

A method for computing shape sensitivity in the frame of non‐linear and non‐steady‐state forging is presented. Derivatives of tool geometry, velocity and state variables with respect to the shape parameters are calculated by a direct differentiation of discrete equations. Because of the important part played by the accuracy of finite element calculations, an efficient transfer method is used between meshes during remeshings and the contact algorithms are carefully differentiated. The resulting inverse design procedure is successfully applied to two industrial examples of forging of automobile parts, with fold‐over and piping defects occurring during the intermediate designs. It makes it possible to suggest reasonable preform shapes, with or without any available knowledge of the forging process. Copyright © 2001 John Wiley & Sons, Ltd.     

Shape optimization of bonded patch to cylindrical shell structures

Adhesive bonding has been widely used to join or repair metallic and composite structural components to achieve or restore their designated structural stiffness and strengths. However, current analysis methods and empirical databases for composite bonded patch repairs or joints are limited to flat structures, and there exists a very limited knowledge on the effect of curvature on the performance and durability of composite bonded joints and repairs. Recently, a novel finite element formulation was presented for developing adhesive elements for conducting 2.5‐D simplified stress analysis of bonded repairs to curved structures. This paper presents the work on optimal shape design of a bonded curved composite patch using the newly developed adhesive element. The Sequential Linear Programming (SLP) method is employed as the optimization algorithm in conjunction with a fully implemented mesh generation algorithm into which new features have been incorporated. The objective of shape optimization is to minimize the maximum stress in the entire adhesive layer to ensure that the bonded patch effectively works together with the parent structure in service. Several different objective functions, related to possible failure mechanisms of the adhesive layer, are proposed to optimize the shape of a bonded patch. Copyright © 2003 John Wiley & Sons, Ltd.     

Continuum‐based design sensitivity analysis and optimization of nonlinear shell structures using meshfree method

A continuum‐based shape and configuration design sensitivity analysis (DSA) method for a finite deformation elastoplastic shell structure has been developed. Shell elastoplasticity is treated using the projection method that performs the return mapping on the subspace defined by the zero‐normal stress condition. An incrementally objective integration scheme is used in the context of finite deformation shell analysis, wherein the stress objectivity is preserved for finite rotation increments. The material derivative concept is used to develop a continuum‐based shape and configuration DSA method. Significant computational efficiency is obtained by solving the design sensitivity equation without iteration at each converged load step using the same consistent tangent stiffness matrix. Numerical implementation of the proposed shape and configuration DSA is carried out using the meshfree method. The accuracy and efficiency of the proposed method is illustrated using numerical examples. Copyright © 2006 John Wiley & Sons, Ltd.     

A structural optimization method based on the level set method using a new geometry‐based re‐initialization scheme

Structural optimization methods based on the level set method are a new type of structural optimization method where the outlines of target structures can be implicitly represented using the level set function, and updated by solving the so‐called Hamilton–Jacobi equation based on a Eulerian coordinate system. These new methods can allow topological alterations, such as the number of holes, during the optimization process whereas the boundaries of the target structure are clearly defined. However, the re‐initialization scheme used when updating the level set function is a critical problem when seeking to obtain appropriately updated outlines of target structures. In this paper, we propose a new structural optimization method based on the level set method using a new geometry‐based re‐initialization scheme where both the numerical analysis used when solving the equilibrium equations and the updating process of the level set function are performed using the Finite Element Method. The stiffness maximization, eigenfrequency maximization, and eigenfrequency matching problems are considered as optimization problems. Several design examples are presented to confirm the usefulness of the proposed method. Copyright © 2010 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.     

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.     

Geometrical design of thermoelectric generators based on topology optimization

This paper discusses an application of the topology optimization method for the design of thermoelectric generators. The proposed methodology provides the optimized geometry in accordance with various arbitrary conditions such as the types of materials, the volume of materials, and the temperature and shape of the installation position. By considering the coupled equations of state for the thermoelectric problem, we introduce an analytical model subject to these equations, which mimics the closed circuit composed of thermoelectric materials, electrodes, and a resistor. The total electric power applied to the resistor and the conversion efficiency are formulated as objective functions to be optimized. The proposed optimization method for thermoelectric generators is implemented as a geometrical optimization method using the solid isotropic material with penalization method used in topology optimizations. Simple relationships are formulated between the density function of the solid isotropic material with penalization method and the physical properties of the thermoelectric material. A sensitivity analysis for the objective functions is formulated with respect to the density function and the adjoint equations required for calculating it. Depending on the sensitivity, the density function is updated using the method of moving asymptotes. Finally, numerical examples are provided to demonstrate the validity of the proposed method. Copyright © 2012 John Wiley & Sons, Ltd.     

一种新型高效的结构优化设计方法研究

在设计开发的通用优化平台中,采用模块化结构,集成了现有有限元分析软件与自行研制开发的高效优化方法。在有限元分析软件中完成结构特性分析,并提取节点、单元、实常数等信息及分析结果,在优化平台中调用自行设计的优化方法完成优化计算。该方法既充分利用了现有有限元分析软件强大的分析功能和高效优化方法的优越性,同时避免了优化程序设计中重复开发有限元分析部分,提高了优化效率。甘蔗收割机台架结构的优化实例表明了该方法的有效性与实用性。     

Generalized Timoshenko modelling of composite beam structures: sensitivity analysis and optimal design

This article describes a new approach to design the cross-section layer orientations of composite laminated beam structures. The beams are modelled with realistic cross-sectional geometry and material properties instead of a simplified model. The VABS (the variational asymptotic beam section analysis) methodology is used to compute the cross-sectional model for a generalized Timoshenko model, which was embedded in the finite element solver FEAP. Optimal design is performed with respect to the layers’ orientation. The design sensitivity analysis is analytically formulated and implemented. The direct differentiation method is used to evaluate the response sensitivities with respect to the design variables. Thus, the design sensitivities of the Timoshenko stiffness computed by VABS methodology are imbedded into the modified VABS program and linked to the beam finite element solver. The modified method of feasible directions and sequential quadratic programming algorithms are used to seek the optimal continuous solution of a set of numerical examples. The buckling load associated with the twist–bend instability of cantilever composite beams, which may have several cross-section geometries, is improved in the optimization procedure.     

T‐spline finite element method for the analysis of shell structures

A T‐spline surface is a nonuniform rational B‐spline (NURBS) surface with T‐junctions, and is defined by a control grid called T‐mesh. The T‐mesh is similar to a NURBS control mesh except that in a T‐mesh, a row or column of control points is allowed to terminate in the inner parametric space. This property of T‐splines makes local refinement possible. In the present study, shell formulation based on the T‐spline finite element method (FEM) is presented. Shell formulation based on NURBS or T‐splines has fundamental limitations because rotational DOFs, which are necessary in the shell formulation, cannot be defined on control points. In this study, the simple mapping scheme, in which every control point is mapped into one geometric point on the surface, is employed to eliminate the limitations. Using this mapping scheme, T‐spline FEM can be easily extended to the analysis of shells. The proposed shell formulation is verified through various benchmarking problems. This study is a part of the efforts by the authors for the integration of CAD–CAE processes. Copyright © 2009 John Wiley & Sons, Ltd.     

Shape optimization of periodic structures

This paper describes a numerical approach to the optimization of effective properties of periodic perforations in an infinite body, in the frameworks of heat conduction and of linear elasticity. We implement a special finite element mesh in order to deal with the periodic nature of the problem. We compute the gradient of the functional to be minimized. We describe the process of mesh deformation and mesh regeneration. We give several numerical examples, some of them having practical relevance.     

Optimal control of an induction heating process using automatic differentiation

We consider an optimal control problem arising in an induction heating process. The main difficulty is to obtain accurate and efficient derivatives of the discrete form of the cost function. In this work we use automatic differentiation. Unlike numerical differentiation based on finite differences, derivatives generated by automatic differentiation are free of truncation error. Numerical results show the performance of the method in terms of accuracy and computational efficiency. Copyright © 2005 John Wiley & Sons, Ltd.     

Sensitivities of flow and transport parameters in fractured porous media using automatic differentiation

The hydraulic complexity of hardrock aquifers with, for example, fast fluid flow in fractures, storage effects in the rock matrix, high contrasts in permeability, and a high spatial variability of structures requires a high standard of experimental and numerical techniques. This paper focuses on the interpretation of tracer tests. The sensitivity of tracer breakthrough curves with respect to flow and transport parameters is analysed for different model types in order to identify the relevant flow and transport processes. This leads to a better understanding of the system behaviour and facilitates the interpretation of experimental results. The technique of automatic differentiation is used to evaluate the sensitivities. The main advantage of this technique is that the sensitivities are calculated without truncation error. Copyright © 2005 John Wiley & Sons, Ltd.     

Optimal control of thermal fluid flow using automatic differentiation

The aim of this study is to present a method for numerical optimal control of thermal fluid flow using automatic differentiation (AD). For the optimal control, governing equations are required. The optimal controls that have been previously presented by the present authors’ research group are based on the Boussinesq equations. However, because the numerical results of these equations are not satisfactory, the compressible Navier–Stokes equations are employed in this study. The objective is to determine whether or not the temperature at the objective points can be kept constant by imposing boundary conditions and by controlling the temperature at the control points. To measure the difference between the computed and target temperatures, the square sum of these values is used. The objective points are located at the center of the computational domain while the control points are at the bottom of the computational domain. The weighted gradient method that employs AD for efficiently calculating the gradient is used for the minimization. By using numerical computations, we show the validity of the present method.     

Topology optimization using bi-directional evolutionary structural optimization based on the element-free Galerkin method

In this article, the bi-directional evolutionary structural optimization (BESO) method based on the element-free Galerkin (EFG) method is presented for topology optimization of continuum structures. The mathematical formulation of the topology optimization is developed considering the nodal strain energy as the design variable and the minimization of compliance as the objective function. The EFG method is used to derive the shape functions using the moving least squares approximation. The essential boundary conditions are enforced by the method of Lagrange multipliers. Several topology optimization problems are presented to show the effectiveness of the proposed method. Many issues related to topology optimization of continuum structures, such as chequerboard patterns and mesh dependency, are studied in the examples.     

A hybrid topology optimization algorithm for static and vibrating shell structures

Structural designers are reconsidering traditional design procedures using structural optimization techniques. Although shape and sizing optimization techniques have facilitated a great improvement in the emergence of new optimum designs, they are still limited by the fact that a suitable topology must be assumed initially. In this paper a hybrid algorithm entitled constrained adaptive topology optimization, or CATO is introduced. The algorithm, based on an artificial material model and an adaptive updating scheme, combines ideas from the mathematically rigorous homogenization (h) methods and the intuitive evolutionary (e) methods. The algorithm is applied to shell structures under static or free vibration situations. For the static situation, the objective is to produce the stiffest structure subject to given loading conditions, boundary conditions and material properties. For the free vibration situation, the objective is to maximize or minimize a chosen frequency. In both cases, a constraint on the structural volume/mass is applied and the optimization process is achieved by redistributing the material through the shell structure. The efficiency of the proposed algorithm is illustrated through several numerical examples of shells under either static or free vibration situations. Copyright © 2002 John Wiley & Sons, Ltd.     

Applying functional principal components to structural topology optimization

Structural topology optimization aims to enhance the mechanical performance of a structure while satisfying some functional constraints. Nearly all approaches proposed in the literature are iterative, and the optimal solution is found by repeatedly solving a finite element analysis (FEA). It is thus clear that the bottleneck is the high computational effort, as these approaches require solving the FEA a large number of times. In this work, we address the need for reducing the computational time by proposing a reduced basis method that relies on functional principal component analysis (FPCA). The methodology has been validated considering a simulated annealing approach for compliance minimization in 2 classical variable thickness problems. Results show the capability of FPCA to provide good results while reducing the computational times, ie, the computational time for an FEA is about one order of magnitude lower in the reduced FPCA space.     

Discrete material optimization of general composite shell structures

A novel method for doing material optimization of general composite laminate shell structures is presented and its capabilities are illustrated with three examples. The method is labelled Discrete Material Optimization (DMO) but uses gradient information combined with mathematical programming to solve a discrete optimization problem. The method can be used to solve the orientation problem of orthotropic materials and the material selection problem as well as problems involving both. The method relies on ideas from multiphase topology optimization to achieve a parametrization which is very general and reduces the risk of obtaining a local optimum solution for the tested configurations. The applicability of the DMO method is demonstrated for fibre angle optimization of a cantilever beam and combined fibre angle and material selection optimization of a four‐point beam bending problem and a doubly curved laminated shell. Copyright © 2005 John Wiley & Sons, Ltd.     

基于复合优化方法立式数控加工中心的多目标优化设计

为实现加工中心动静态性能不低于优化前性能,达到整机重量最轻的要求,本文提出了一种复合优化方法来研究多变量、多约束和多目标的数控加工中心优化设计。采用有限元分析和实验模态测试方法分析各大件动态性能,并验证了有限元模型的精确性。然后以该有限元模型为基础进行静态分析,得出各大件的最大变形及应力等。以柔度为目标,采用变密度法拓扑优化设计立柱结构的外形框架;以固有频率为目标,基于元结构的可适应性动态优化方法设计加工中心的筋板结构;以固有频率和质量为目标,基于响应面法的尺寸优化确定各结构的最优尺寸。最后将优化后的各大件进行整机装配,分析校核整机动静态性能。分析结果表明,优化后的整机在保证加工中心动静态性能的条件下,整机质量从12749kg减少到12127kg,减重达到4.9%,达到了整机的优化设计要求,说明该方法具有较高的精度和较强的工程实用性。