Design sensitivity analysis and optimization for minimizing springback of sheet‐formed part

The springback is a manufacturing defect in the stamping process and causes difficulty in product assembly. An impediment to the use of lighter‐weight, higher‐strength materials in manufacturing is relative lack of understanding about how these materials respond to complex forming processes. The springback can be reduced by using an optimized combination of die, punch, and blank holder shapes together with friction and blank‐holding force. An optimized process can be determined using a gradient‐based optimization to minimize the springback. For an effective optimization of the stamping process, development of an efficient design sensitivity analysis (DSA) for the springback with respect to these process parameters is crucial. A continuum‐based shape and configuration DSA method for the stamping process has been developed using a non‐linear shell model. The material derivative is used to develop the continuum‐based design sensitivity. The design sensitivity equation is solved without iteration at each converged load step in the finite deformation elastoplastic non‐linear analysis with frictional contact, which makes sensitivity calculation very efficient. Numerical implementation of the proposed shape and configuration DSA method is performed using the meshfree method. The accuracy and efficiency of the proposed method are illustrated by minimizing the springback in a benchmark S‐rail problem. Copyright © 2007 John Wiley & Sons, Ltd.     

Post optimization for accurate and efficient reliability‐based design optimization using second‐order reliability method based on importance sampling and its stochastic sensitivity analysis

In this study, a post optimization technique for a correction of inaccurate optimum obtained using first‐order reliability method (FORM) is proposed for accurate reliability‐based design optimization (RBDO). In the proposed method, RBDO using FORM is first performed, and then the proposed second‐order reliability method (SORM) is performed at the optimum obtained using FORM for more accurate reliability assessment and its sensitivity analysis. In the proposed SORM, the Hessian of a performance function is approximated by reusing derivatives information accumulated during previous RBDO iterations using FORM, indicating that additional functional evaluations are not required in the proposed SORM. The proposed SORM calculates a probability of failure and its first‐order and second‐order stochastic sensitivity by applying the importance sampling to a complete second‐order Taylor series of the performance function. The proposed post optimization constructs a second‐order Taylor expansion of the probability of failure using results of the proposed SORM. Because the constructed Taylor expansion is based on the reliability method more accurate than FORM, the corrected optimum using this Taylor expansion can satisfy the target reliability more accurately. In this way, the proposed method simultaneously achieves both efficiency of FORM and accuracy of SORM. Copyright © 2015 John Wiley & Sons, Ltd.     

Meshfree analysis and design sensitivity analysis for shell structures

A unified design sensitivity analysis method for a meshfree shell structure with respect to size, shape, and configuration design variables is presented in this paper. A shear deformable shell formulation is characterized by a CAD connection, thickness degeneration, meshfree discretization, and nodal integration. Because of a strong connection to the CAD tool, the design variable is selected from the CAD parameters, and a consistent design velocity field is then computed by perturbing the surface geometric matrix. The material derivative concept is utilized in order to obtain a design sensitivity equation in the parametric domain. Numerical examples show the accuracy and efficiency of the proposed design sensitivity analysis method compared to the analytical solution and the finite difference solution. Copyright © 2002 John Wiley & Sons, Ltd.     

Die shape design optimization of sheet metal stamping process using meshfree method

A die shape design sensitivity analysis (DSA) and optimization for a sheet metal stamping process is proposed based on a Lagrangian formulation. A hyperelasticity‐based elastoplastic material model is used for the constitutive relation that includes a large deformation effect. The contact condition between a workpiece and a rigid die is imposed through the penalty method with a modified Coulomb friction model. The domain of the workpiece is discretized by a meshfree method. A continuum‐based DSA with respect to the rigid die shape parameter is formulated using a design velocity concept. The die shape perturbation has an effect on structural performance through the contact variational form. The effect of the deformation‐dependent pressure load to the design sensitivity is discussed. It is shown that the design sensitivity equation uses the same tangent stiffness matrix as the response analysis. The linear design sensitivity equation is solved at each converged load step without the need of iteration, which is quite efficient in computation. The accuracy of sensitivity information is compared to that of the finite difference method with an excellent agreement. A die shape design optimization problem is solved to obtain the desired shape of the workpiece to minimize spring‐back effect and to show the feasibility of the proposed method. Copyright © 2001 John Wiley & Sons, Ltd.     

Variational sensitivity analysis of a nonlinear solid shell element

The paper is concerned with variational sensitivity analysis of a nonlinear solid shell element, which is based on the Hu–Washizu variational principle. The sensitivity information is derived on the continuous level and discretized to yield the analytical expressions on the computational level. Especially, the pseudo load matrix and the sensitivity matrix, which dominate design sensitivity analysis of shape optimization problems, are derived. Because of the mixed formulation, condensation of the pseudo load matrix on the element level is performed to compute the sensitivity matrix. An illustrative example from the field of geometry‐based shape optimization demonstrates the possible application of the presented formulation. Copyright © 2013 John Wiley & Sons, Ltd.     

基于有限元灵敏度分析的预锻模具形状优化设计

在控制锻件几何形状的前提下 ,采用有限元灵敏度分析方法 ,对预锻模具形状进行优化设计 .针对下模速度为零时 ,速度灵敏度边界条件为零 ,其形状在优化迭代过程中得不到优化的情况 ,对速度灵敏度边界条件提出改进措施 ,使上下模具形状同时能够得到优化 .最后给出了优化设计实例 ,验证该方法的可靠性 .     

A bispace parameterization method for shape optimization of thin‐walled curved shell structures with openings

Simultaneous shape optimization of thin‐walled curved shell structures and involved hole boundaries is studied in this paper. A novel bispace parameterization method is proposed for the first time to define global and local shape design variables both in the Cartesian coordinate system and the intrinsic coordinate system. This method has the advantage of achieving a simultaneous optimization of the global shape of the shell surface and the local shape of the openings attached automatically on the former. Inherent problems, for example, the effective parameterization of shape design variables, mapping operation between two spaces, and sensitivity analysis with respect to both kinds of design variables are highlighted. A design procedure is given to show how both kinds of design variables are managed together and how the whole design flowchart is carried out with relevant formulations. Numerical examples are presented and the effects of both kinds of design variables upon the optimal solutions are discussed. Copyright © 2012 John Wiley & Sons, Ltd.     

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.     

Finite element response sensitivity analysis using force‐based frame models

This paper presents a method to compute consistent response sensitivities of force‐based finite element models of structural frame systems to both material constitutive and discrete loading parameters. It has been shown that force‐based frame elements are superior to classical displacement‐based elements in the sense that they enable, at no significant additional costs, a drastic reduction in the number of elements required for a given level of accuracy in the computed response of the finite element model. This advantage of force‐based elements is of even more interest in structural reliability analysis, which requires accurate and efficient computation of structural response and structural response sensitivities. This paper focuses on material non‐linearities in the context of both static and dynamic response analysis. The formulation presented herein assumes the use of a general‐purpose non‐linear finite element analysis program based on the direct stiffness method. It is based on the general so‐called direct differentiation method (DDM) for computing response sensitivities. The complete analytical formulation is presented at the element level and details are provided about its implementation in a general‐purpose finite element analysis program. The new formulation and its implementation are validated through some application examples, in which analytical response sensitivities are compared with their counterparts obtained using forward finite difference (FFD) analysis. The force‐based finite element methodology augmented with the developed procedure for analytical response sensitivity computation offers a powerful general tool for structural response sensitivity analysis. Copyright © 2004 John Wiley & Sons, Ltd.     

Explicit level‐set‐based topology optimization using an exact Heaviside function and consistent sensitivity analysis

This paper presents a level‐set‐based topology optimization method based on numerically consistent sensitivity analysis. The proposed method uses a direct steepest‐descent update of the design variables in a level‐set method; the level‐set nodal values. An exact Heaviside formulation is used to relate the level‐set function to element densities. The level‐set function is not required to be a signed‐distance function, and reinitialization is not necessary. Using this approach, level‐set‐based topology optimization problems can be solved consistently and multiple constraints treated simultaneously. The proposed method leads to more insight in the nature of level‐set‐based topology optimization problems. The level‐set‐based design parametrization can describe gray areas and numerical hinges. Consistency causes results to contain these numerical artifacts. We demonstrate that alternative parameterizations, level‐set‐based or density‐based regularization can be used to avoid artifacts in the final results. The effectiveness of the proposed method is demonstrated using several benchmark problems. The capability to treat multiple constraints shows the potential of the method. Furthermore, due to the consistency, the optimizer can run into local minima; a fundamental difficulty of level‐set‐based topology optimization. More advanced optimization strategies and more efficient optimizers may increase the performance in the future. Copyright © 2012 John Wiley & Sons, Ltd.     

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.     

Nonlinear manifold learning for meshfree finite deformation thin‐shell analysis

Calculations on general point‐set surfaces are attractive because of their flexibility and simplicity in the preprocessing but present important challenges. The absence of a mesh makes it nontrivial to decide if two neighboring points in the three‐dimensional embedding are nearby or rather far apart on the manifold. Furthermore, the topology of surfaces is generally not that of an open two‐dimensional set, ruling out global parametrizations. We propose a general and simple numerical method analogous to the mathematical theory of manifolds, in which the point‐set surface is described by a set of overlapping charts forming a complete atlas. We proceed in four steps: (1) partitioning of the node set into subregions of trivial topology; (2) automatic detection of the geometric structure of the surface patches by nonlinear dimensionality reduction methods; (3) parametrization of the surface using smooth meshfree (here maximum‐entropy) approximants; and (4) gluing together the patch representations by means of a partition of unity. Each patch may be viewed as a meshfree macro‐element. We exemplify the generality, flexibility, and accuracy of the proposed approach by numerically approximating the geometrically nonlinear Kirchhoff–Love theory of thin‐shells. We analyze standard benchmark tests as well as point‐set surfaces of complex geometry and topology. Copyright © 2012 John Wiley & Sons, Ltd.     

An isogeometric‐meshfree coupling approach for analysis of cracks

This paper presents a new concurrent simulation approach to couple isogeometric analysis (IGA) with the meshfree method for studying of crack problems. In the present method, the overall physical domain is divided into 2 subdomains that are formulated with the IGA and meshfree method, respectively. In the meshfree subdomain, the moving least squares shape function is adopted for the discretization of the area around crack tips, and the IGA subdomain is adopted in the remaining area. Meanwhile, the interface region between the 2 subdomains is represented by coupled shape functions. The resulting shape function, which comprises both IGA and meshfree shape functions, satisfies the consistency condition, thus ensuring convergence of the method. Moreover, the meshfree shape functions augmented with the enriched basis functions to predict the singular stress fields near a crack tip are presented. The proposed approach is also applied to simulate the crack propagation under a mixed‐mode condition. Several numerical examples are studied to demonstrate the use and robustness of the proposed method.     

Performance‐based design sensitivity analysis of steel moment frames under earthquake loading

A performance‐based design sensitivity analysis procedure for inelastic steel moment frameworks under equivalent static earthquake loading is presented in this paper. Analytical formulations defining the sensitivity of displacements to modifications in member sizes are derived based on a load‐control pushover analysis procedure. Material non‐linearity under bending moment is alone accounted. Although the formulations were derived based on continuous design variables, they are readily extended to the case of discrete design variables. A 3‐storey moment frame example illustrates the applicability and accuracy of the developed methodology. Copyright © 2005 John Wiley & Sons, Ltd.     

An isogeometric locking‐free NURBS‐based solid‐shell element for geometrically nonlinear analysis

In this work, we develop an isogeometric non‐uniform rational B‐spline (NURBS)‐based solid‐shell element for the geometrically nonlinear static analysis of elastic shell structures. A single layer of continuous 3D elements through the thickness of the shell is considered, and the order of approximation in that direction is chosen to be equal to two. A complete 3D constitutive relation is assumed. The objective is to develop a highly accurate low‐order element for coarse meshes. We propose an extension of the mixed method of Bouclier et al. [11] to deal with locking in the context of large rotations and large displacements. The main idea is to modify the interpolation of the average through the thickness of the stress components. It is also necessary to stabilize the element in order to avoid the occurrence of spurious zero‐energy modes. This was achieved, for the quadratic version, through the adjunction of artificial elementary stabilization stiffnesses. The result is an element of order 2, which is at least as accurate as standard NURBS shell elements of order 4. Linear and nonlinear test calculations have been carried out along with comparisons with other published NURBS and classical techniques in order to assess the performance of the element. Copyright © 2014 John Wiley & Sons, Ltd.     

A continuum sensitivity method for finite thermo‐inelastic deformations with applications to the design of hot forming processes

A computational framework is presented to evaluate the shape as well as non‐shape (parameter) sensitivity of finite thermo‐inelastic deformations using the continuum sensitivity method (CSM). Weak sensitivity equations are developed for the large thermo‐mechanical deformation of hyperelastic thermo‐viscoplastic materials that are consistent with the kinematic, constitutive, contact and thermal analyses used in the solution of the direct deformation problem. The sensitivities are defined in a rigorous sense and the sensitivity analysis is performed in an infinite‐dimensional continuum framework. The effects of perturbation in the preform, die surface, or other process parameters are carefully considered in the CSM development for the computation of the die temperature sensitivity fields. The direct deformation and sensitivity deformation problems are solved using the finite element method. The results of the continuum sensitivity analysis are validated extensively by a comparison with those obtained by finite difference approximations (i.e. using the solution of a deformation problem with perturbed design variables). The effectiveness of the method is demonstrated with a number of applications in the design optimization of metal forming processes. Copyright © 2002 John Wiley & Sons, Ltd.     

Improvement of semi‐analytical design sensitivities of non‐linear structures using equilibrium relations

The accuracy problem of the semi‐analytical method for shape design sensitivity analysis has been reported for linear and non‐linear structures. The source of error is the numerical differentiation of the element internal force vector, which is inherent to the semi‐analytical approach. Such errors occur for structures whose displacement field is characterized by large rigid body rotations of individual elements. This paper presents a method for the improvement of semi‐analytical sensitivities. The method is based on the element free body equilibrium conditions, and on the exact differentiation of the rigid body modes. The method is efficient, simple to code, and can be applied to linear and non‐linear structures. The numerical examples show that this approach eliminates the abnormal errors that occur in the conventional semi‐analytical method. Copyright © 2001 John Wiley & Sons, Ltd.     

Voigt–Reuss topology optimization for structures with nonlinear material behaviors

This work is directed toward optimizing concept designs of structures featuring inelastic material behaviours by using topology optimization. In the proposed framework, alternative structural designs are described with the aid of spatial distributions of volume fraction design variables throughout a prescribed design domain. Since two or more materials are permitted to simultaneously occupy local regions of the design domain, small-strain integration algorithms for general two-material mixtures of solids are developed for the Voigt (isostrain) and Reuss (isostress) assumptions, and hybrid combinations thereof. Structural topology optimization problems involving non-linear material behaviours are formulated and algorithms for incremental topology design sensitivity analysis (DSA) of energy type functionals are presented. The consistency between the structural topology design formulation and the developed sensitivity analysis algorithms is established on three small structural topology problems separately involving linear elastic materials, elastoplastic materials, and viscoelastic materials. The good performance of the proposed framework is demonstrated by solving two topology optimization problems to maximize the limit strength of elastoplastic structures. It is demonstrated through the second example that structures optimized for maximal strength can be significantly different than those optimized for minimal elastic compliance. © 1997 John Wiley & Sons, Ltd.