Weakly and fully coupled methods for structural optimization of flexible mechanisms

The paper concerns a detailed comparison between two optimization methods that are used to perform the structural optimization of flexible components within a multibody system (MBS) simulation. The dynamic analysis of flexible MBS is based on a nonlinear finite element formulation. The first method is a weakly coupled method, which reformulates the dynamic response optimization problem in a two-level approach. First, a rigid or flexible MBS simulation is performed, and second, each component is optimized independently using a quasi-static approach in which a series of equivalent static load (ESL) cases obtained from the MBS simulation are applied to the respective components. The second method, the fully coupled method, performs the dynamic response optimization using the time response obtained directly from the flexible MBS simulation. Here, an original procedure is proposed to evaluate the ESL from a nonlinear finite element simulation, contrasting with the floating reference frame formulation exploited in the standard ESL method. Several numerical examples are provided to support our position. It is shown that the fully coupled method is more general and accommodates all types of constraints at the price of a more complex optimization process.     

System-Based Approaches for Structural Optimization of Flexible Mechanisms

This paper reviews the state-of-the-art methods to perform structural optimization of flexible mechanisms. These methods are based on a system-based approach, i.e. the formulation of the design problem incorporates the time response of the mechanism that is obtained from a dynamic simulation of the flexible multibody system. The system-based approach aims at considering as precisely as possible the effects of nonlinear dynamic loading under various operating conditions. Also, the optimization process enhances most existing studies which are limited to (quasi-) static or frequency domain loading conditions. This paper briefly introduces flexible multibody system dynamics and structural optimization techniques. Afterwards, the two main methods, named the weakly and the fully coupled methods, that couple both disciplines are presented in details and the influence of the multibody system formalism is analyzed. The advantages and drawbacks of both methods are discussed and future possible research areas are mentioned.     

Structural topology optimization of multibody systems

Flexible multibody dynamics (FMD) has found many applications in control, analysis and design of mechanical systems. FMD together with the theory of structural optimization can be used for designing multibody systems with bodies which are lighter, but stronger. Topology optimization of static structures is an active research topic in structural mechanics. However, the extension to the dynamic case is less investigated as one has to face serious numerical difficulties. One way of extending static structural topology optimization to topology optimization of dynamic flexible multibody system with large rotational and transitional motion is investigated in this paper. The optimization can be performed simultaneously on all flexible bodies. The simulation part of optimization is based on an FEM approach together with modal reduction. The resulting nonlinear differential-algebraic systems are solved with the error controlled integrator IDA (Sundials) wrapped into Python environment by Assimulo (Andersson et al. in Math. Comput. Simul. 116(0):26–43, 2015). A modified formulation of solid isotropic material with penalization (SIMP) method is suggested to avoid numerical instabilities and convergence failures of the optimizer. Sensitivity analysis is central in structural optimization. The sensitivities are approximated to circumvent the expensive calculations. The provided examples show that the method is indeed suitable for optimizing a wide range of multibody systems. Standard SIMP method in structural topology optimization suggests stiffness penalization. To overcome the problem of instabilities and mesh distortion in the dynamic case we consider here additionally element mass penalization.     

On the influence of model reduction techniques in topology optimization of flexible multibody systems using the floating frame of reference approach

Employing the floating frame of reference formulation in the topology optimization of dynamically loaded components of flexible multibody systems seems to be a natural choice. In this formulation the deformation of flexible bodies is approximated by global shape functions, which are commonly obtained from finite element models using model reduction techniques. For topology optimization these finite element models can be parameterized using the solid isotropic material with penalization (SIMP) approach. However, little is known about the interplay of model reduction and SIMP parameterization. Also securing the model reduction quality despite major changes of the design during the optimization has not been addressed yet. Thus, using the examples of a flexible frame and a slider-crank mechanism this work discusses the proper choice of the model reduction technique in the topology optimization of flexible multibody systems.     

变拓扑柔性多体系统接触碰撞动力学研究

在实际工程领域中存在着大量接触碰撞等非连续动力学问题,现有的解决柔性多体系统连续动力学过程的建模理论与方法,已经无法解决或无法很好解决这些问题.本文基于变拓扑思想,提出了附加接触约束的柔性多体系统碰撞动力学建模理论；通过设计柔性圆柱杆接触碰撞实验,验证了所提出附加约束接触碰撞模型的有效性；针对柔性多体系统全局动力学仿真面临时间和空间的多尺度问题,提出多变量的离散方法,从而提高了柔性多体系统非连续动力学的仿真效率.     

Optimization of flexible components of multibody systems via equivalent static loads

An optimization methodology that iteratively links the results of multibody dynamics and structural analysis software to an optimization method is presented to design flexible multibody systems under dynamic loading conditions. In particular, rigid multibody dynamic analysis is utilized to calculate dynamic loads of a multibody system and a structural optimization algorithm using equivalent static loads transformed from the dynamic loads are used to design the flexible components in the multibody dynamic system. The equivalent static loads, which are derived from equations of motion, are used as multiple loading conditions of linear structural optimization. A simple example is solved to verify the proposed methodology and the pelvis part of the biped humanoid, a complex multibody system which consists of many bodies and joints, is redesigned using the proposed methodology.     

Structural sensitivity analysis of flexible multibody systems modeled with the floating frame of reference approach using the adjoint variable method

For the efficient analysis and optimization of flexible multibody systems, gradient information is often required. Next to simple and easy-to-implement finite difference approaches, analytical methods, such as the adjoint variable method, have been developed and are now well established for the sensitivity analysis in multibody dynamics. They allow the computation of exact gradients and require normally less computational effort for large-scale problems. In the current work, we apply the adjoint variable method to flexible multibody systems with kinematic loops, which are modeled using the floating frame of reference formulation. Thereby, in order to solve ordinary differential equations only, the equations of motion are brought into minimal form using coordinate partitioning, and the constraint equations at position and velocity level are incorporated in the adjoint dynamics. For testing and illustrative purposes, the procedure is applied to compute the structural gradient for a flexible piston rod of a slider–crank mechanism.     

First order sensitivity analysis of flexible multibody systems using absolute nodal coordinate formulation

Design sensitivity analysis of flexible multibody systems is important in optimizing the performance of mechanical systems. The choice of coordinates to describe the motion of multibody systems has a great influence on the efficiency and accuracy of both the dynamic and sensitivity analysis. In the flexible multibody system dynamics, both the floating frame of reference formulation (FFRF) and absolute nodal coordinate formulation (ANCF) are frequently utilized to describe flexibility, however, only the former has been used in design sensitivity analysis. In this article, ANCF, which has been recently developed and focuses on modeling of beams and plates in large deformation problems, is extended into design sensitivity analysis of flexible multibody systems. The Motion equations of a constrained flexible multibody system are expressed as a set of index-3 differential algebraic equations (DAEs), in which the element elastic forces are defined using nonlinear strain-displacement relations. Both the direct differentiation method and adjoint variable method are performed to do sensitivity analysis and the related dynamic and sensitivity equations are integrated with HHT-I3 algorithm. In this paper, a new method to deduce system sensitivity equations is proposed. With this approach, the system sensitivity equations are constructed by assembling the element sensitivity equations with the help of invariant matrices, which results in the advantage that the complex symbolic differentiation of the dynamic equations is avoided when the flexible multibody system model is changed. Besides that, the dynamic and sensitivity equations formed with the proposed method can be efficiently integrated using HHT-I3 method, which makes the efficiency of the direct differentiation method comparable to that of the adjoint variable method when the number of design variables is not extremely large. All these improvements greatly enhance the application value of the direct differentiation method in the engineering optimization of the ANCF-based flexible multibody systems.     

Erratum to: New efficient method for dynamic modeling and simulation of flexible multibody systems moving in plane

Efficient, precise dynamic analysis for general flexible multibody systems has become a research focus in the field of flexible multibody dynamics. In this paper, the finite element method and component mode synthesis are introduced to describe the deformations of the flexible components, and the dynamic equations of flexible bodies moving in plane are deduced. By combining the discrete time transfer matrix method of multibody system with these dynamic equations of flexible component, the transfer equations and transfer matrices of flexible bodies moving in plane are developed. Finally, a high-efficient dynamic modeling method and its algorithm are presented for high-speed computation of general flexible multibody dynamics. Compared with the ordinary dynamics methods, the proposed method combines the strengths of the transfer matrix method and finite element method. It does not need the global dynamic equations of system and has the low order of system matrix and high computational efficiency. This method can be applied to solve the dynamics problems of flexible multibody systems containing irregularly shaped flexible components. It has advantages for dynamic design of complex flexible multibody systems. Formulations as well as a numerical example of a multi-rigid-flexible-body system containing irregularly shaped flexible components are given to validate the method.     

New efficient method for dynamic modeling and simulation of flexible multibody systems moving in plane

Efficient, precise dynamic analysis for general flexible multibody systems has become a research focus in the field of flexible multibody dynamics. In this paper, the finite element method and component mode synthesis are introduced to describe the deformations of the flexible components, and the dynamic equations of flexible bodies moving in plane are deduced. By combining the discrete time transfer matrix method of multibody system with these dynamic equations of flexible component, the transfer equations and transfer matrices of flexible bodies moving in plane are developed. Finally, a high-efficient dynamic modeling method and its algorithm are presented for high-speed computation of general flexible multibody dynamics. Compared with the ordinary dynamics methods, the proposed method combines the strengths of the transfer matrix method and finite element method. It does not need the global dynamic equations of system and has the low order of system matrix and high computational efficiency. This method can be applied to solve the dynamics problems of flexible multibody systems containing irregularly shaped flexible components. It has advantages for dynamic design of complex flexible multibody systems. Formulations as well as a numerical example of a multi-rigid-flexible-body system containing irregularly shaped flexible components are given to validate the method.     

Topology optimization in OpenMDAO

Recently, topology optimization has drawn interest from both industry and academia as the ideal design method for additive manufacturing. Topology optimization, however, has a high entry barrier as it requires substantial expertise and development effort. The typical numerical methods for topology optimization are tightly coupled with the corresponding computational mechanics method such as a finite element method and the algorithms are intrusive, requiring an extensive understanding. This paper presents a modular paradigm for topology optimization using OpenMDAO, an open-source computational framework for multidisciplinary design optimization. This provides more accessible topology optimization algorithms that can be non-intrusively modified and easily understood, making them suitable as educational and research tools. This also opens up further opportunities to explore topology optimization for multidisciplinary design problems. Two widely used topology optimization methods—the density-based and level-set methods—are formulated in this modular paradigm. It is demonstrated that the modular paradigm enhances the flexibility of the architecture, which is essential for extensibility.

     

Technical overview of the equivalent static loads method for non-linear static response structural optimization

Linear static response structural optimization has been developed fairly well by using the finite element method for linear static analysis. However, development is extremely slow for structural optimization where a non linear static analysis technique is required. Optimization methods using equivalent static loads (ESLs) have been proposed to solve various structural optimization disciplines. The disciplines include linear dynamic response optimization, structural optimization for multi-body dynamic systems, structural optimization for flexible multi-body dynamic systems, nonlinear static response optimization and nonlinear dynamic response optimization. The ESL is defined as the static load that generates the same displacement field by an analysis which is not linear static. An analysis that is not linear static is carried out to evaluate the displacement field. ESLs are evaluated from the displacement field, linear static response optimization is performed by using the ESLs, and the design is updated. This process proceeds in a cyclic manner. A variety of problems have been solved by the ESLs methods. In this paper, the methods are completely overviewed. Various case studies are demonstrated and future research of the methods is discussed.     

Sensitivity Analysis of Rigid-Flexible Multibody Systems

An important step in the application of automated design techniques to rigid-flexible multibody systems is the calculation of the sensitivities with respect to design variables. Thispaper presents a general formulation for thecalculation of the first order analytical designsensitivities based on the direct differentiationmethod. The analytical sensitivities are comparedwith the numerical results obtained by the finitedifferences method and the accuracy and validity ofboth methods is discussed. Cartesian co-ordinates areused for the dynamic analysis of rigid-flexiblemultibody systems. To reduce the number ofco-ordinates associated with the flexible bodies, thecomponent mode synthesis method is used. Theequations of the sensitivities are obtainedsymbolically and integrated in time simultaneouslywith the dynamic equations. Examples of 2Dsensitivity analysis of the transient response of aslider-crank and of a vehicle with a flexible chassisare presented, and the accuracy and characteristics ofthe sensitivities are analyzed and discussed.     

A level set approach for optimal design of smart energy harvesters

The proliferation of Micro-Electro-Mechanical Systems (MEMS), portable electronics and wireless sensing networks has raised the need for a new class of devices with self-powering capabilities. Vibration-based piezoelectric energy harvesters provide a very promising solution, as a result of their capability of converting mechanical energy into electrical energy through the direct piezoelectric effect. However, the identification of fast, accurate methods and rational criteria for the design of piezoelectric energy harvesting devices still poses a challenge. In this work, a level set-based topology optimization approach is proposed to synthesize mechanical energy harvesting devices for self-powered micro systems. The energy harvester design problem is reformulated as a variational problem based on the concept of topology optimization, where the optimal geometry is sought by maximizing the energy conversion efficiency of the device. To ensure computational efficiency, the shape gradient of the energy conversion efficiency is analytically derived using the material time derivative approach and the adjoint variable method. A design velocity field is then constructed using the steepest descent method, which is further integrated into level set methods. The reconciled level set (RLS) method is employed to solve multi-material shape and topology optimization problems, using the Merriman–Bence–Osher (MBO) operator. Designs with both single and multiple materials are presented, which constitute improvements with respect to existing energy harvesting designs.     

A review of optimization of structures subjected to transient loads

Various aspects of structural optimization techniques under transient loads are extensively reviewed. The main themes of the paper are treatment of time-dependent constraints, calculation of design sensitivity, and approximation. Each subject is reviewed with corresponding papers that have been published since the 1970s. The treatment of time-dependent constraints in both the direct method and the transformation method is discussed. Two ways of calculating design sensitivity of a structure under transient loads are discussed—direct differentiation method and adjoint variable method. The approximation concept mainly focuses on the response surface method in crashworthiness and local approximation with the intermediate variables. Especially, a method using the equivalent static load is discussed as an approximation method. It takes advantage of the well-established static response optimization. The structural optimization in flexible multibody dynamic systems is reviewed in the viewpoint of the above three themes.     

Topology optimization based on level set for a flexible multibody system modeled via ANCF

A topology optimization methodology is proposed for the flexible multibody system undergoing both large overall motion and large deformation. The system of concern is modeled via the absolute nodal coordinate formulation. The equivalent static load method is employed to transform the topology optimization of the nonlinear dynamic response of the system into a static one, and evaluated to adapt to the absolute nodal coordinate formulation by splitting the elastic deformations of the flexible components from the overall motions of those components. During the static topology optimization, the material interface is implicitly described as the zero level set of a higher-dimensional scalar function. Then, the semi-implicit level set method with the additive operator splitting algorithm is employed to solve the corresponding Hamilton-Jacobi partial differential equation. In addition, the expert evaluation method of weights based on the grey theory is utilized to define the objective function, and a modified augmented Lagrange multiplier method is proposed to treat the inequality volume constraint so as to avoid the oscillation and drift of the volume. Finally, two numerical examples are provided to validate the proposed methodology.     

Optimization of a complex flexible multibody systems with composite materials

The paper presents a general optimization methodology for flexible multibody systems which is demonstrated to find optimal layouts of fiber composite structures components. The goal of the optimization process is to minimize the structural deformation and, simultaneously, to fulfill a set of multidisciplinary constraints, by finding the optimal values for the fiber orientation of composite structures. In this work, a general formulation for the computation of the first order analytical sensitivities based on the use of automatic differentiation tools is applied. A critical overview on the use of the sensitivities obtained by automatic differentiation against analytical sensitivities derived and implemented by hand is made with the purpose of identifying shortcomings and proposing solutions. The equations of motion and sensitivities of the flexible multibody system are solved simultaneously being the accelerations and velocities of the system and the sensitivities of the accelerations and of the velocities integrated in time using a multi-step multi-order integration algorithm. Then, the optimal design of the flexible multibody system is formulated to minimize the deformation energy of the system subjected to a set of technological and functional constraints. The methodologies proposed are first discussed for a simple demonstrative example and applied after to the optimization of a complex flexible multibody system, represented by a satellite antenna that is unfolded from its launching configuration to its functional state.     

Interaction of flexible multibody systems with fluids analyzed by means of smoothed particle hydrodynamics

The present work deals with a computational approach to fluid-structure interaction (FSI) problems by coupling of flexible multibody system dynamics and fluid dynamics. Since the methods for the numerical modeling are well known, both for the structural and the fluid part, the focus of this work lies on the coupling formalism. Moreover, the applicability of the presented approach to arbitrary geometries and high structural stiffness is studied, as well as an easy model setup. No restriction should be made on the topology of the structure or the complexity of motion.For the fluid part a meshless method, known as smoothed particle hydrodynamics (SPH) is applied, which fulfills the above requirements. While an explicit time integration scheme in SPH provides a fast simulation of the fluid dynamics, advanced methods from flexible multibody dynamics provide a variety of benefits for the simulation of the solid part. Amongst these are specialized structural finite elements for both small and large deformation bodies, joints, stable implicit time-integration schemes, and model reduction techniques.A rule for the interaction between fluids and structures is derived from imposing a distributed potential over boundary segments of the structures, which the fluid particles respond to. The work is concluded by illustrative examples, demonstrating the successful coupling of flexible multibody systems with fluids.     

A Krylov–Arnoldi reduced order modelling framework for efficient,fully coupled,structural–acoustic optimization

In this work, a reduced order multidisciplinary optimization procedure is developed to enable efficient, low frequency, undamped and damped, fully coupled, structural–acoustic optimization of interior cavities backed by flexible structural systems. This new method does not require the solution of traditional eigen value based problems to reduce computational time during optimization, but are instead based on computation of Arnoldi vectors belonging to the induced Krylov Subspaces. The key idea of constructing such a reduced order model is to remove the uncontrollable, unobservable and weakly controllable, observable parts without affecting the noise transfer function of the coupled system. In a unified approach, the validity of the optimization framework is demonstrated on a constrained composite plate/prism cavity coupled system. For the fully coupled, vibro–acoustic, unconstrained optimization problem, the design variables take the form of stacking sequences of a composite structure enclosing the acoustic cavity. The goal of the optimization is to reduce sound pressure levels at the driver’s ear location. It is shown that by incorporating the reduced order modelling procedure within the optimization framework, a significant reduction in computational time can be obtained, without any loss of accuracy—when compared to the direct method. The method could prove as a valuable tool to analyze and optimize complex coupled structural–acoustic systems, where, in addition to fast analysis, a fine frequency resolution is often required.     

Parallel framework for topology optimization using the method of moving asymptotes

The complexity of problems attacked in topology optimization has increased dramatically during the past decade. Examples include fully coupled multiphysics problems in thermo-elasticity, fluid-structure interaction, Micro-Electro Mechanical System (MEMS) design and large-scale three dimensional problems. The only feasible way to obtain a solution within a reasonable amount of time is to use parallel computations in order to speed up the solution process. The focus of this article is on a fully parallel topology optimization framework implemented in C++, with emphasis on utilizing well tested and simple to implement linear solvers and optimization algorithms. However, to ensure generality, the code is developed to be easily extendable in terms of physical models as well as in terms of solution methods, without compromising the parallel scalability. The widely used Method of Moving Asymptotes optimization algorithm is parallelized and included as a fundamental part of the code. The capabilities of the presented approaches are demonstrated on topology optimization of a Stokes flow problem with target outflow constraints as well as the minimum compliance problem with a volume constraint from linear elasticity.