Reducing dimensionality in topology optimization using adaptive design variable fields

Topology optimization methodologies typically use the same discretization for the design variable and analysis meshes. Analysis accuracy and expense are thus directly tied to design dimensionality and optimization expense. This paper proposes leveraging properties of the Heaviside projection method (HPM) to separate the design variable field from the analysis mesh in continuum topology optimization. HPM projects independent design variables onto element space over a prescribed length scale. A single design variable therefore influences several elements, creating a redundancy within the design that can be exploited to reduce the number of independent design variables without significantly restricting the design space. The algorithm begins with sparse design variable fields and adapts these fields as the optimization progresses. The technique is demonstrated on minimum compliance (maximum stiffness) problems solved using continuous optimization and genetic algorithms. For the former, the proposed algorithm typically identifies solutions having objective functions within 1% of those found using full design variable fields. Computational savings are minor to moderate for the minimum compliance formulation with a single constraint, and are substantial for formulations having many local constraints. When using genetic algorithms, solutions are consistently obtained on mesh resolutions that were previously considered intractable. Copyright © 2009 John Wiley & Sons, Ltd.     

A moving superimposed finite element method for structural topology optimization

Level set methods are becoming an attractive design tool in shape and topology optimization for obtaining efficient and lighter structures. In this paper, a dynamic implicit boundary‐based moving superimposed finite element method (s‐version FEM or S‐FEM) is developed for structural topology optimization using the level set methods, in which the variational interior and exterior boundaries are represented by the zero level set. Both a global mesh and an overlaying local mesh are integrated into the moving S‐FEM analysis model. A relatively coarse fixed Eulerian mesh consisting of bilinear rectangular elements is used as a global mesh. The local mesh consisting of flexible linear triangular elements is constructed to match the dynamic implicit boundary captured from nodal values of the implicit level set function. In numerical integration using the Gauss quadrature rule, the practical difficulty due to the discontinuities is overcome by the coincidence of the global and local meshes. A double mapping technique is developed to perform the numerical integration for the global and coupling matrices of the overlapped elements with two different co‐ordinate systems. An element killing strategy is presented to reduce the total number of degrees of freedom to improve the computational efficiency. A simple constraint handling approach is proposed to perform minimum compliance design with a volume constraint. A physically meaningful and numerically efficient velocity extension method is developed to avoid the complicated PDE solving procedure. The proposed moving S‐FEM is applied to structural topology optimization using the level set methods as an effective tool for the numerical analysis of the linear elasticity topology optimization problems. For the classical elasticity problems in the literature, the present S‐FEM can achieve numerical results in good agreement with those from the theoretical solutions and/or numerical results from the standard FEM. For the minimum compliance topology optimization problems in structural optimization, the present approach significantly outperforms the well‐recognized ‘ersatz material’ approach as expected in the accuracy of the strain field, numerical stability, and representation fidelity at the expense of increased computational time. It is also shown that the present approach is able to produce structures near the theoretical optimum. It is suggested that the present S‐FEM can be a promising tool for shape and topology optimization using the level set methods. Copyright © 2005 John Wiley & Sons, Ltd.     

Multiresolution topology optimization using isogeometric analysis

The paper introduces a novel multiresolution scheme to topology optimization in the framework of the isogeometric analysis. A new variable parameter space is added to implement multiresolution topology optimization based on the Solid Isotropic Material with Penalization approach. Design density variables defined in the variable space are used to approximate the element analysis density by the bivariate B‐spline basis functions, which are easily obtained using k‐refinement strategy in the isogeometric analysis. While the nonuniform rational B‐spline basis functions are used to exactly describe geometric domains and approximate unknown solutions in finite element analysis. By applying a refined sensitivity filter, optimized designs include highly discrete solutions in terms of solid and void materials without using any black and white projection filters. The Method of Moving Asymptotes is used to solve the optimization problem. Various benchmark test problems including plane stress, compliant mechanism inverter, and 2‐dimensional heat conduction are examined to demonstrate the effectiveness and robustness of the present method.     

基于映射的拓扑优化最大尺寸控制方法

拓扑优化方法经过几十年的发展,已成功应用于机械工程、航空航天、电磁等领域的构型设计中。然而,由于制造工艺的限制,拓扑优化结果通常无法直接应用,需根据工艺要求进行修改,因此在拓扑优化模型中考虑制造约束成为重要的研究方向。其中,尺寸控制广泛存在于大部分制造工艺中,主要包括最小尺寸控制与最大尺寸控制。该文提出了一种基于映射的拓扑优化最大尺寸控制方法,构造了一种新的映射模型,对结构中不满足最大尺寸约束的中心单元密度进行惩罚,在不引入任何约束条件的情况下实现了对结构最大尺寸的控制。此外,该文将该方法中的惩罚转变为一个全局约束条件后与具有最小尺寸控制功能的拓扑优化鲁棒列式相结合,实现了对构件的最大最小尺寸协同控制。数值算例表明了该方法的有效性。     

Hierarchical remeshing strategies with mesh mapping for topology optimisation

This work investigates the use of hierarchical mesh decomposition strategies for topology optimisation using bi‐directional evolutionary structural optimisation algorithm. The proposed method uses a dual mesh system that decouples the design variables from the finite element analysis mesh. The investigation focuses on previously unexplored areas of these techniques to investigate the effect of five meshing parameters on the analysis solving time (i.e. computational effort) and the analysis quality (i.e. solution optimality). The foreground mesh parameters, including adjacency ratio and minimum and maximum element size, were varied independently across solid and void domain regions. Within the topology optimisation, strategies for controlling the mesh parameters were investigated. The differing effects of these parameters on the efficiency and efficacy of the analysis and optimisation stages are discussed, and recommendations are made for parameter combinations. Some of the key findings were that increasing the adjacency ratio increased the efficiency only modestly – the largest effect was for the minimum and maximum element size parameters – and that the most dramatic reduction in solve time can be achieved by not setting the minimum element size too low, assuming mapping onto a background mesh with a minimum element size of 1. © 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.     

考虑混合约束的柔顺机构拓扑优化设计

为了满足制造工艺和静强度要求,提出一种综合考虑最小尺寸控制和应力约束的柔顺机构混合约束拓扑优化设计方法。采用改进的固体各向同性材料插值模型描述材料分布,利用多相映射方法同时控制实相和空相材料结构的最小尺寸,采用最大近似函数P范数求解机构的最大应力,以机构的输出位移最大化作为目标函数,综合考虑最小特征尺寸控制和应力约束建立柔顺机构混合约束拓扑优化数学模型,利用移动渐近算法求解柔顺机构混合约束拓扑优化问题。数值算例结果表明,混合约束拓扑优化获得的柔顺机构能够同时满足最小尺寸制造约束和静强度要求,机构的von Mises等效应力分布更加均匀。     

考虑混合约束的柔顺机构拓扑优化设计

为了满足制造工艺和静强度要求,提出一种综合考虑最小尺寸控制和应力约束的柔顺机构混合约束拓扑优化设计方法。采用改进的固体各向同性材料插值模型描述材料分布,利用多相映射方法同时控制实相和空相材料结构的最小尺寸,采用最大近似函数P范数求解机构的最大应力,以机构的输出位移最大化作为目标函数,综合考虑最小特征尺寸控制和应力约束建立柔顺机构混合约束拓扑优化数学模型,利用移动渐近算法求解柔顺机构混合约束拓扑优化问题。数值算例结果表明,混合约束拓扑优化获得的柔顺机构能够同时满足最小尺寸制造约束和静强度要求,机构的von Mises等效应力分布更加均匀。     

Hybrid finite element/volume method for shallow water equations

A hybrid numerical scheme based on finite element and finite volume methods is developed to solve shallow water equations. In the recent past, we introduced a series of hybrid methods to solve incompressible low and high Reynolds number flows for single and two‐fluid flow problems. The present work extends the application of hybrid method to shallow water equations. In our hybrid shallow water flow solver, we write the governing equations in non‐conservation form and solve the non‐linear wave equation using finite element method with linear interpolation functions in space. On the other hand, the momentum equation is solved with highly accurate cell‐center finite volume method. Our hybrid numerical scheme is truly a segregated method with primitive variables stored and solved at both node and element centers. To enhance the stability of the hybrid method around discontinuities, we introduce a new shock capturing which will act only around sharp interfaces without sacrificing the accuracy elsewhere. Matrix‐free GMRES iterative solvers are used to solve both the wave and momentum equations in finite element and finite volume schemes. Several test problems are presented to demonstrate the robustness and applicability of the numerical method. Copyright © 2010 John Wiley & Sons, Ltd.     

An immersed boundary element method for level‐set based topology optimization

In this paper, we propose a new BEM for level‐set based topology optimization. In the proposed BEM, the nodal coordinates of the boundary element are replaced with the nodal level‐set function and the nodal coordinates of the Eulerian mesh that maintains the level‐set function. Because this replacement causes the nodal coordinates of the boundary element to disappear, the boundary element mesh appears to be immersed in the Eulerian mesh. Therefore, we call the proposed BEM an immersed BEM. The relationship between the nodal coordinates of the boundary element and the nodal level‐set function of the Eulerian mesh is clearly represented, and therefore, the sensitivities with respect to the nodal level‐set function are strictly derived in the immersed BEM. Furthermore, the immersed BEM completely eliminates grayscale elements that are known to cause numerical difficulties in topology optimization. By using the immersed BEM, we construct a concrete topology optimization method for solving the minimum compliance problem. We provide some numerical examples and discuss the usefulness of the constructed optimization method on the basis of the obtained results. Copyright © 2012 John Wiley & Sons, Ltd.     

The XFEM for high‐gradient solutions in convection‐dominated problems

Convection‐dominated problems typically involve solutions with high gradients near the domain boundaries (boundary layers) or inside the domain (shocks). The approximation of such solutions by means of the standard finite element method requires stabilization in order to avoid spurious oscillations. However, accurate results may still require a mesh refinement near the high gradients. Herein, we investigate the extended finite element method (XFEM) with a new enrichment scheme that enables highly accurate results without stabilization or mesh refinement. A set of regularized Heaviside functions is used for the enrichment in the vicinity of the high gradients. Different linear and non‐linear problems in one and two dimensions are considered and show the ability of the proposed enrichment to capture arbitrary high gradients in the solutions. Copyright © 2009 John Wiley & Sons, Ltd.     

Influence of pattern gradation on the design of piezocomposite energy harvesting devices using topology optimization

Piezoelectric materials can be used to convert oscillatory mechanical energy into electrical energy. Energy harvesting devices are designed to capture the ambient energy surrounding the electronics and convert it into usable electrical energy. The design of energy harvesting devices is not obvious, requiring optimization procedures. This paper investigates the influence of pattern gradation using topology optimization on the design of piezocomposite energy harvesting devices based on bending behavior. The objective function consists of maximizing the electric power generated in a load resistor. A projection scheme is employed to compute the element densities from design variables and control the length scale of the material density. Examples of two-dimensional piezocomposite energy harvesting devices are presented and discussed using the proposed method. The numerical results illustrate that pattern gradation constraints help to increase the electric power generated in a load resistor and guides the problem toward a more stable solution.     

A velocity field level set method for shape and topology optimization

In this paper, we propose a new implementation of the level set shape and topology optimization, the velocity field level set method. Therein, the normal velocity field is constructed with specified basis functions and velocity design variables defined on a given set of points that are independent of the finite element mesh. A general mathematical programming algorithm can be employed to find the optimal normal velocities on the basis of the sensitivity analysis. As compared with conventional level set methods, mapping the variational boundary shape optimization problem into a finite‐dimensional design space and the use of a general optimizer makes it more efficient and straightforward to handle multiple constraints and additional design variables. Moreover, the level set function is updated by the Hamilton‐Jacobi equation using the normal velocity field; thus, the inherent merits of the implicit representation is retained. Therefore, this method combines the merits of both the general mathematical programming and conventional level set methods. Integrated topology optimization of structures with embedded components of designable geometries is considered to show the capability of this method to deal with general design variables. Several numerical examples in 2D or 3D design domains illustrate the robustness and efficiency of the method using different basis functions.     

General topology optimization method with continuous and discrete orientation design using isoparametric projection

A general topology optimization method, which is capable of simultaneous design of density and orientation of anisotropic material, is proposed by introducing orientation design variables in addition to the density design variable. In this work, the Cartesian components of the orientation vector are utilized as the orientation design variables. The proposed method supports continuous orientation design, which is out of the scope of discrete material optimization approaches, as well as design using discrete angle sets. The advantage of this approach is that vector element representation is less likely to fail into local optima because it depends less on designs of former steps, especially compared with using the angle as a design variable (Continuous Fiber Angle Optimization) by providing a flexible path from one angle to another with relaxation of orientation design space. An additional advantage is that it is compatible with various projection or filtering methods such as sensitivity filters and density filters because it is free from unphysical bound or discontinuity such as the one at θ = 2π and θ = 0 seen with direct angle representation. One complication of Cartesian component representation is the point‐wise quadratic bound of the design variables; that is, each pair of element values has to reside in a given circular bound. To overcome this issue, we propose an isoparametric projection method, which transforms box bounds into circular bounds by a coordinate transformation with isoparametric shape functions without having the singular point that is seen at the origin with polar coordinate representation. A new topology optimization method is built by taking advantage of the aforementioned features and modern topology optimization techniques. Several numerical examples are provided to demonstrate its capability. Copyright © 2014 John Wiley & Sons, Ltd.     

Integrated layout design of multi‐component system

A new integrated layout optimization method is proposed here for the design of multi‐component systems. By introducing movable components into the design domain, the components layout and the supporting structural topology are optimized simultaneously. The developed design procedure mainly consists of three parts: (i) Introduction of non‐overlap constraints between components. The finite circle method (FCM) is used to avoid the components overlaps and also overlaps between components and the design domain boundaries. (ii) Layout optimization of the components and supporting structure. Locations and orientations of the components are assumed as geometrical design variables for the optimal placement while topology design variables of the supporting structure are defined by the density points. Meanwhile, embedded meshing techniques are developed to take into account the finite element mesh change caused by the component movements. (iii) Consistent material interpolation scheme between element stiffness and inertial load. The commonly used solid isotropic material with penalization model is improved to avoid the singularity of localized deformation in the presence of design dependent loading when the element stiffness and the involved inertial load are weakened by the element material removal. Finally, to validate the proposed design procedure, a variety of multi‐component system layout design problems are tested and solved on account of inertia loads and gravity center position constraint. Solutions are compared with traditional topology designs without component. Copyright © 2008 John Wiley & Sons, Ltd.     

Stochastic projection schemes for deterministic linear elliptic partial differential equations on random domains

We present stochastic projection schemes for approximating the solution of a class of deterministic linear elliptic partial differential equations defined on random domains. The key idea is to carry out spatial discretization using a combination of finite element methods and stochastic mesh representations. We prove a result to establish the conditions that the input uncertainty model must satisfy to ensure the validity of the stochastic mesh representation and hence the well posedness of the problem. Finite element spatial discretization of the governing equations using a stochastic mesh representation results in a linear random algebraic system of equations in a polynomial chaos basis whose coefficients of expansion can be non‐intrusively computed either at the element or the global level. The resulting randomly parametrized algebraic equations are solved using stochastic projection schemes to approximate the response statistics. The proposed approach is demonstrated for modeling diffusion in a square domain with a rough wall and heat transfer analysis of a three‐dimensional gas turbine blade model with uncertainty in the cooling core geometry. The numerical results are compared against Monte–Carlo simulations, and it is shown that the proposed approach provides high‐quality approximations for the first two statistical moments at modest computational effort. Copyright © 2010 John Wiley & Sons, Ltd.     

Improvements in the reliability and element quality of parallel tetrahedral mesh generation

The paper presents a parallel tetrahedral mesh generation approach based on recursive bidivisions using triangular surfaces. Research was conducted for addressing issues concerning mesh generation reliability and element quality. A novel procedure employing local modification techniques is proposed for repairing the intersecting interdomain mesh instead of directly repeating the bidivision procedure, which improves the robustness of the complete meshing procedure significantly. In addition, a new parallel quality improvement scheme is suggested for optimizing the distributed volume meshes. The scheme is free of any communication cost and highly efficient. Finally, mesh experiments of hundreds of millions of elements are performed to demonstrate the reliability, effectiveness and efficiency of the proposed method and its potential applications to large‐scale simulations of complex aerodynamics models. Copyright © 2012 John Wiley & Sons, Ltd.     

A nonlocal multiscale discrete‐continuum model for predicting mechanical behavior of granular materials

A three‐dimensional nonlocal multiscale discrete‐continuum model has been developed for modeling mechanical behavior of granular materials. In the proposed multiscale scheme, we establish an information‐passing coupling between the discrete element method, which explicitly replicates granular motion of individual particles, and a finite element continuum model, which captures nonlocal overall responses of the granular assemblies. The resulting multiscale discrete‐continuum coupling method retains the simplicity and efficiency of a continuum‐based finite element model, while circumventing mesh pathology in the post‐bifurcation regime by means of staggered nonlocal operator. We demonstrate that the multiscale coupling scheme is able to capture the plastic dilatancy and pressure‐sensitive frictional responses commonly observed inside dilatant shear bands, without employing a phenomenological plasticity model at a macroscopic level. In addition, internal variables, such as plastic dilatancy and plastic flow direction, are now inferred directly from granular physics, without introducing unnecessary empirical relations and phenomenology. The simple shear and the biaxial compression tests are used to analyze the onset and evolution of shear bands in granular materials and sensitivity to mesh density. The robustness and the accuracy of the proposed multiscale model are verified in comparisons with single‐scale benchmark discrete element method simulations. Copyright © 2015 John Wiley & Sons, Ltd.     

Hierarchical enrichment for bridging scales and mesh‐free boundary conditions

The finite‐element method, when used with a basis made up of piecewise polynomials, often requires the generation of a very fine computational mesh in order to capture localized solution phenomena such as boundary layers or near‐singularities. Enrichment of the basis with additional functions, obtained through analytical or experimental means, can allow for a coarser mesh and more accurate solution. We introduce an enrichment scheme in which an interaction or ‘bridging’ scale term is used to separate the basis formed by the enrichment functions from the original set of basis functions, in effect making the enrichment hierarchical. This separation of scales allows the simple application of essential boundary conditions. It also allows a quantification of the effects of the enrichment, leading to strategies for error estimation and control of the stiffness matrix condition number. We also find that this formulation allows for the simple application of essential boundary conditions for mesh‐free shape functions, which are notoriously problematic. We find that for multiple dimensions, care must be taken to derive a weak form which is truly consistent with the strong form on the essential boundary. Copyright © 2001 John Wiley & Sons, Ltd.     

Linear and nonlinear topology optimization design with projection-based ground structure method (P-GSM)

A new topology optimization scheme called the projection-based ground structure method (P-GSM) is proposed for linear and nonlinear topology optimization designs. For linear design, compared to traditional GSM which are limited to designing slender members, the P-GSM can effectively resolve this limitation and generate functionally graded lattice structures. For additive manufacturing-oriented design, the manufacturing abilities are the key factors to constrain the feasible design space, for example, minimum length and geometry complexity. Conventional density-based method, where each element works as a variable, always results in complex geometry with large number of small intricate features, while these small features are often not manufacturable even by 3D printing and lose its geometric accuracy after postprocessing. The proposed P-GSM is an effective method for controlling geometric complexity and minimum length for optimal design, while it is capable of designing self-supporting structures naturally. In optimization progress, some bars may be disconnected from each other (floating in the air). For buckling-induced design, this issue becomes critical due to severe mesh distortion in the void space caused by disconnection between members, while P-GSM has ability to overcome this issue. To demonstrate the effectiveness of proposed method, three different design problems ranging from compliance optimization to buckling-induced mechanism design are presented and discussed in details.