Convergence of topological patterns of optimal periodic structures under multiple scales

The current techniques for topology optimization of material microstructure are typically based on infinitely small and periodically repeating base cells. These base cells have no actual size. It is uncertain whether the topology of the microstructure obtained from such a material design approach could be translated into real structures of macroscale. In this work we have carried out a first systematic study on the convergence of topological patterns of optimal periodic structures, the extreme case of which is a material microstructure with infinitesimal base cells. In a series of numerical experiments, periodic structures under various loading and boundary conditions are optimized for stiffness and frequency. By increasing the number of unit cells, we have found that the topologies of the unit cells converge rapidly to certain patterns. It is envisaged that if we continue to increase the number of unit cells and thus reduce the size of each unit cell until it becomes the infinitesimal material base cell, the optimal topology of the unit cell would remain the same. The finding from this work is of significant practical importance and theoretical implication because the same topological pattern designed for given loading and boundary conditions could be used as the optimal solution for the periodic structure of vastly different scales, from a structure with a few (e.g. 20) repetitive modules to a material microstructure with an infinite number of base cells.     

Topology optimization of structures with integral compliant mechanisms for mid-frequency response

The purpose of this paper is to present a method for developing new truss-like sandwich structures that exhibit desirable mid-frequency vibratory characteristics. Specifically, a genetic algorithm optimization routine is used to determine candidate small scale structural topologies, i.e. unit cells, that may be used in the design of larger scale periodic sandwich structures. This multi-scale procedure is demonstrated starting with several unit cell topology optimization examples. From these examples a specific optimal unit cell is selected for further investigation and integration into a periodic sandwich beam. Computational results indicate that the proposed optimization approach is effective when used to design new structures for reduced mid-frequency vibratory response.     

Design of phononic crystals for self-collimation of elastic waves using topology optimization method

Self-collimating phononic crystals (PCs) are periodic structures that enable self-collimation of waves. While various design parameters such as material property, period, lattice symmetry, and material distribution in a unit cell affect wave scattering inside a PC, this work aims to find an optimal material distribution in a unit cell that exhibits the desired self-collimation properties. While earlier studies were mainly focused on the arrangement of self-collimating PCs or shape changes of inclusions in a unit cell having a specific topological layout, we present a topology optimization formulation to find a desired material distribution. Specifically, a finite element based formulation is set up to find the matrix and inclusion material distribution that can make elastic shear-horizontal bulk waves propagate along a desired target direction. The proposed topology optimization formulation newly employs the geometric properties of equi-frequency contours (EFCs) in the wave vector space as essential elements in forming objective and constraint functions. The sensitivities of these functions with respect to design variables are explicitly derived to utilize a gradient-based optimizer. To show the effectiveness of the formulation, several case studies are considered.     

Multi-material topology optimization with multiple volume constraints: a general approach applied to ground structures with material nonlinearity

Multi-material topology optimization is a practical tool that allows for improved structural designs. However, most studies are presented in the context of continuum topology optimization – few studies focus on truss topology optimization. Moreover, most work in this field has been restricted to linear material behavior with limited volume constraint settings for multiple materials. To address these issues, we propose an efficient multi-material topology optimization formulation considering material nonlinearity. The proposed formulation handles an arbitrary number of candidate materials with flexible material properties, features freely specified material layers, and includes a generalized volume constraint setting. To efficiently handle such arbitrary volume constraints, we derive a design update scheme that performs robust updates of the design variables associated with each volume constraint independently. The derivation is based on the separable feature of the dual problem of the convex approximated primal subproblem with respect to the Lagrange multipliers, and thus the update of design variables in each volume constraint only depends on the corresponding Lagrange multiplier. Through examples in 2D and 3D, using combinations of Ogden-based, bilinear, and linear materials, we demonstrate that the proposed multi-material topology optimization framework with the presented update scheme leads to a design tool that not only finds the optimal topology but also selects the proper type and amount of material. The design update scheme is named ZPR (phonetically, zipper), after the initials of the authors’ last names (Zhang-Paulino-Ramos Jr.).     

Size-dependent optimal microstructure design based on couple-stress theory

The purpose of this paper is to propose a size-dependent topology optimization formulation of periodic cellular material microstructures, based on the effective couple-stress continuum model. The present formulation consists of finding the optimal layout of material that minimizes the mean compliance of the macrostructure subject to the constraint of permitted material volume fraction. We determine the effective macroscopic couple-stress constitutive constants by analyzing a unit cell with specified boundary conditions with the representative volume element (RVE) method, based on equivalence of strain energy. The computational model is established by the finite element (FE) method, and the design density and FE stiffness of the RVE are related by the solid isotropic material with penalization power (SIMP) law. The required sensitivity formulation for gradient-based optimization algorithm is also derived. Numerical examples demonstrate that this present formulation can express the size effect during the optimization procedure and provide precise topologies without increase in computational cost.     

On the (non-)optimality of Michell structures

Optimal analytical Michell frame structures have been extensively used as benchmark examples in topology optimization, including truss, frame, homogenization, density and level-set based approaches. However, as we will point out, partly the interpretation of Michell’s structural continua as discrete frame structures is not accurate and partly, it turns out that limiting structural topology to frame-like structures is a rather severe design restriction and results in structures that are quite far from being stiffness optimal. The paper discusses the interpretation of Michell’s theory in the context of numerical topology optimization and compares various topology optimization results obtained with the frame restriction to cases with no design restrictions. For all examples considered, the true stiffness optimal structures are composed of sheets (2D) or closed-walled shell structures (3D) with variable thickness. For optimization problems with one load case, numerical results in two and three dimensions indicate that stiffness can be increased by up to 80 % when dropping the frame restriction. For simple loading situations, studies based on optimal microstructures reveal theoretical gains of +200 %. It is also demonstrated how too coarse design discretizations in 3D can result in unintended restrictions on the design freedom and achievable compliance.     

On the prediction of topology and local properties for optimal trussed structures

A new formulation is presented for mathematical modelling to predict the distribution of material, material properties, and topology for the optimal design of trussed structures. The design problem is cast in a form to minimize a measure ofgeneralized compliance, which is calculated as a sum over the structure of weighted displacement. Member stiffnesses appear as design variables and, starting with a given ground structure, the solution predicts the optimal layout and distribution of stiffness. The isoperimetric constraint in the reformulated problem measures totalcost in generalized form, based on independently specified unit relative cost factors for each truss element. One or another form of optimal design is generated via a process where designated elements in the unit relative cost field are adjusted systematically at each cycle. The generalized cost feature provides as well for the introduction of certain technical constraints into the design problem, e.g. the facility to design around obstacles. Results for each cycle of an algorithm for computational treatment are identified as the solution to a properly posed optimization problem. Computational procedures are demonstrated by the prediction of optimal designs for a variety of truss problems in 2D.     

On globally stable singular truss topologies

We consider truss topology optimization problems including a global stability constraint, which guarantees a sufficient elastic stability of the optimal structures. The resulting problem is a nonconvex semi-definite program, for which nonconvex interior point methods are known to show the best performance. We demonstrate that in the framework of topology optimization, the global stability constraint may behave similarly to stress constraints, that is, that some globally optimal solutions are singular and cannot be approximated from the interior of the design domain. This behaviour, which may be called a global stability singularity phenomenon, prevents convergence of interior point methods towards globally optimal solutions. We propose a simple perturbation strategy, which restores the regularity of the design domain. Further, to each perturbed problem interior point methods can be applied.     

Topology optimization of continuum structures subjected to the variance constraint of reaction forces

In this paper, the attainment of uniform reaction forces at the specific fixed boundary is investigated for topology optimization of continuum structures. The variance of the reaction forces at the boundary between the elastic solid and its foundation is firstly introduced as the evaluation criterion of the uniformity of the reaction forces. Then, the standard formulation of optimal topology design is improved by introducing the variance constraint of the reaction forces. Sensitivity analysis of the latter is carried out based on the adjoint method. Numerical examples are dealt with to reveal the effect of the variance constraint in comparison with solutions of standard topology optimization.     

Adaptive volume constraint algorithm for stress limit-based topology optimization

Homogenization or density-based topology optimization methods work by distributing a fixed amount of material to the most effective areas of the design domain so as to create an optimal structural configuration that meets the minimum compliance criteria. These topology optimization methods generally cannot control the maximum stress levels of the structure; therefore, the smoothened optimum structure is not guaranteed to be ready for immediate use. This can be because it is either unsafe if the maximum stress at this structure exceeds the strength limit, or over designed if the maximum stress is far below the stress limit. Difficult and complex shape optimization must then be done to obtain a minimum-weight structure that meets the maximum stress constraint. This paper proposes an adaptive volume constraint (AVC) algorithm, a heuristic approach, in place of traditional topology optimization methods so that the maximum stress in the optimal structural configuration will be below the predefined stress limit and the smoothened structure will be directly applicable. In order to test the applicability and robustness of the AVC algorithm, topology optimization using both a traditional fixed volume constraint and an AVC are tested on a number of configuration design problems. To further illustrate the usefulness of the AVC algorithm, shape optimizations at the maximum stress constraint are also conducted on the smooth structural models by both optimization approaches on an identical problem set.     

Constraint force design method for topology optimization of planar rigid-body mechanisms

This study develops a new design method called the constraint force design method, which allows topology optimization for planar rigid-body mechanisms. In conventional mechanism synthesis methods, the kinematics of a mechanism are analytically derived and the positions and types of joints of a fixed configuration (hereafter the topology) are optimized to obtain an optimal rigid-body mechanism tracking the intended output trajectory. Therefore, in conventional methods, modification of the configuration or topology of joints and links is normally considered impossible. In order to circumvent the fixed topology limitation in optimally designing rigid-body mechanisms, we present the constraint force design method. This method distributes unit masses simulating revolute or prismatic joints depending on the number of assigned degrees of freedom, analyzes the kinetics of unit masses coupled with constraint forces, and designs the existence of these constraint forces to minimize the root-mean-square error of the output paths of synthesized linkages and a target linkage using a genetic algorithm. The applicability and limitations of the newly developed method are discussed in the context of its application to several rigid-body synthesis problems.     

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.     

Wind load modeling for topology optimization of continuum structures

Topology optimization of two and three dimensional structures subject to dead and wind loading is considered. The wind loading is introduced into the formulation by using standard expressions for the drag force, and a strategy is devised so that wind pressure is ignored where there is no surface obstructing the wind. A minimum compliance design formulation is constructed subject to a volume constraint using the Solid Isotropic Material with Penalization model. The optimization problem is solved using the Method of Moving Asymptotes, modified by including a line search and by changing the formula for the update of asymptotes. To obtain black/white design, intermediate density values, which are used as design variables, are controlled by imposing an explicit constraint. Numerical examples of a windmill structure demonstrate that the proposed formulation rationally incorporates the effect of wind loading into the topology optimization problem as illustrated by void appearing in the optimal structure.     

Topological design of modular structures under arbitrary loading

A numerical method for the topological design of periodic continuous domains under general loading is presented. Both the analysis and the design are defined over a single cell. Confining the analysis to the repetitive unit is obtained by the representative cell method which by means of the discrete Fourier transform reduces the original problem to a boundary value problem defined over one module, the representative cell. The repeating module is then meshed into a dense grid of finite elements and solved by finite element analysis. The technique is combined with topology optimization of infinite spatially periodic structures under arbitrary static loading. Minimum compliance structures under a constant volume of material are obtained by using the densities of material as design variables and by satisfying a classical optimality criterion which is generalized to encompass periodic structures. The method is illustrated with the design of an infinite strip possessing 1D translational symmetry and a cyclic structure under a tangential point force. A parametric study presents the evolution of the solution as a function of the aspect ratio of the representative cell.     

Evolutionary topology optimization of continuum structures with a global displacement control

The conventional compliance minimization of load-carrying structures does not directly deal with displacements that are of practical importance. In this paper, a global displacement control is realized through topology optimization with a global constraint that sets a displacement limit on the whole structure or certain sub-domains. A volume minimization problem is solved by an extended evolutionary topology optimization approach. The local displacement sensitivities are derived following a power-law penalization material model. The global control of displacement is realized through multiple local displacement constraints on dynamically located critical nodes. Algorithms are proposed to secure the stability and convergence of the optimization process. Through numerical examples and by comparing with conventional stiffness designs, it is demonstrated that the proposed approach is capable of effectively finding optimal solutions which satisfy the global displacement control. Such solutions are of particular importance for structural designs whose deformed shapes must comply with functioning requirements such as aerodynamic performances.     

A new approach to variable-topology shape design using a constraint on perimeter

This paper introduces a method for variable-topology shape optimization of elastic structures called theperimeter method. An upper-bound constraint on the perimeter of the solid part of the structure ensures a well-posed design problem. The perimeter constraint allows the designer to control the number of holes in the optimal design and to establish their characteristic length scale. Finite element implementations generate practical designs that are convergent with respect to grid refinement. Thus, an arbitrary level of geometric resolution can be achieved, so single-step procedures for topology design and detailed shape design are possible. The perimeter method eliminates the need for relaxation, thereby circumventing many of the complexities and restrictions of other approaches to topology design.     

Generalized topology design of structures with a buckling load criterion

Material based models for topology optimization of linear elastic solids with a low volume constraint generate very slender structures composed mainly of bars and beam elements. For this type of structure the value of the buckling critical load becomes one of the most important design criteria and so its control is very important for meaningful practical designs. This paper tries to address this problem, presenting an approach to introduce the possibility of critical load control into the topology optimization model.Using the material based formulation for topology design of structures, the problem of optimal structural reinforcement for a critical load criterion is formulated. The stability problem is conveniently reduced to a linearized eigenvalue problem assuming only material effective properties and macroscopic instability modes. The respective optimality criteria are presented by introducing the Lagrangian associated with the optimization problem. Based on this Lagrangian a first-order method is used as a basis for the numerical update scheme. Two numerical examples to validate the developments are presented and analysed.     

Topology optimization of microstructures of viscoelastic damping materials for a prescribed shear modulus

Damping performance of a passive constrained layer damping (PCLD) structure mainly depends on the geometric layout and physical properties of the viscoelastic damping material. Properties such as the shear modulus of the damping material need to be tailored for improving the damping of the structures. This paper presents a topology optimization method for designing the microstructures in 2D, i.e., the structure of the periodic unit cell (PUC), of cellular viscoelastic materials with a prescribed shear modulus. The effective behavior of viscoelastic materials is derived through the use of a finite element based homogenization method. Only isotropic matrix material was considered and under such assumption it is found that the effective loss factor of viscoelastic material is independent of the geometrical configuration of the PUC. Based upon the idea of a Solid Isotropic Material with Penalization (SIMP) method of topology optimization, the relative material densities of the elements of the PUC are considered as the design variables. The topology optimization problem of viscoelastic cellular material with a prescribed property and with constraints on the isotropy and volume fraction is established. The optimization problem is solved using the sequential linear programming (SLP) method. Several examples of the design optimization of viscoelastic cellular materials are presented to demonstrate the validity of the method. The effectiveness of the design method is illustrated by comparing a solid and an optimized cellular viscoelastic material as applied to a cantilever beam with the passive constrained layer damping treatment.     

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.