Level-set topology optimization for multimaterial and multifunctional mechanical metamaterials

Metamaterials are artificially engineered composites designed to have unusual properties. This article will develop a new level-set based topology optimization method for the computational design of multimaterial metamaterials with exotic thermomechanical properties. In order to generate metamaterials consisting of arrays of microstructures under periodicity, the numerical homogenization method is used to evaluate the effective properties of the microstructure, and a multiphase level-set model is used to evolve the boundaries of the multimaterial microstructure. The proposed method will produce material geometries with distinct interfaces and smoothed boundaries, which may facilitate the fabrication of the topologically optimized designs. Several numerical cases are used to demonstrate the effectiveness of the proposed method.     

Structural shape and topology optimization based on level-set modelling and the element-propagating method

This article introduces the element-propagating method to structural shape and topology optimization. Structural optimization based on the conventional level-set method needs to solve several partial differential equations. By the insertion and deletion of basic material elements around the geometric boundary, the element-propagating method can avoid solving the partial differential equations and realize the dynamic updating of the material region. This approach also places no restrictions on the signed distance function and the Courant–Friedrichs–Lewy condition for numerical stability. At the same time, in order to suppress the dependence on the design initialization for the 2D structural optimization problem, the strain energy density is taken as a criterion to generate new holes in the material region. The coupled algorithm of the element-propagating method and the method for generating new holes makes the structural optimization more robust. Numerical examples demonstrate that the proposed approach greatly improves numerical efficiency, compared with the conventional level-set method for structural topology optimization.     

Generalized shape optimization of three-dimensional structures using materials with optimum microstructures

This paper deals with generalized shape optimization of linearly elastic, three-dimensional continuum structures, i.e. we consider the problem of determining the structural topology (or layout) such that the shape of external as well as internal boundaries and the number of inner holes are optimized simultaneously. For prescribed static loading and given boundary conditions, the optimum solution is sought from the condition of maximum integral stiffness (minimum elastic compliance) subject to a specified amount of structural material within a given three-dimensional design domain. This generalized shape optimization problem requires relaxation which leads to the introduction of microstructures. A class of optimum three-dimensional microstructures and explicit analytical expressions for their optimum effective stiffness properties have been developed by Gibiansky and Cherkaev (1987) [Gibiansky, L.V., Cherkaev, A.V., 1987. Microstructures of composites of extremal rigidity and exact estimates of provided energy density (in Russian). Report (1987) No. 1155. A.F. Ioffe Physical-Technical Institute, Academy of Sciences of the USSR, Leningrad. English translation in: Kohn, R.V., Cherkaev, A.V. (Eds.), Topics in the Mathematical Modelling of Composite Materials. Birkhaüser, New York. 1997]. The present paper gives a brief account of the results in Gibiansky and Cherkaev (1987) which will be utilized for our microlevel problem analysis. It is a characteristic feature that the use of optimum microstructures renders the global problem convex if an appropriate parametrization is applied. Hereby local optima can be avoided and we can construct a simple gradient based numerical method of mathematical programming for solution of the complete optimization problem. Illustrative examples of optimum layout and topology designs of three-dimensional structures are presented at the end of the paper.     

The stress analysis method for three-dimensional composite materials

This study proposes a stress analysis method for three-dimensionally fiber reinforced composite materials. In this method, the rule-of mixture for composites is successfully applied to 3-D space in which material properties would change 3-dimensionally. The fundamental formulas for Young's modulus, shear modulus, and Poisson's ratio are derived. Also, we discuss a strength estimation and an optimum material design technique for 3-D composite materials. The analysis is executed for a triaxial orthogonally woven fabric, and their results are compared to the experimental data in order to verify the accuracy of this method. The present methodology can be easily understood with basic material mechanics and elementary mathematics, so it enables us to write a computer program of this theory without difficulty. Furthermore, this method can be applied to various types of 3-D composites because of its general-purpose characteristics.     

A material based model for topology optimization of thermoelastic structures

This paper presents the development of a computational model for the topology optimization problem, using a material distribution approach, of a 2-D linear-elastic solid subjected to thermal loads, with a compliance objective function and an isoperimetric constraint on volume. Defining formally the augmented Lagrangian associated with the optimization problem, the optimality conditions are derived analytically. The results of analysis are implemented in a computer code to produce numerical solutions for the optimal topology, considering the temperature distribution independent of design. The design optimization problem is solved via a sequence of linearized subproblems. The computational model developed is tested in example problems. The influence of both the temperature and the finite element model on the optimal solution obtained is analysed.     

Topological optimization for the design of microstructures of isotropic cellular materials

The aim of this study was to design isotropic periodic microstructures of cellular materials using the bidirectional evolutionary structural optimization (BESO) technique. The goal was to determine the optimal distribution of material phase within the periodic base cell. Maximizing bulk modulus or shear modulus was selected as the objective of the material design subject to an isotropy constraint and a volume constraint. The effective properties of the material were found using the homogenization method based on finite element analyses of the base cell. The proposed BESO procedure utilizes the gradient-based sensitivity method to impose the isotropy constraint and gradually evolve the microstructures of cellular materials to an optimum. Numerical examples show the computational efficiency of the approach. A series of new and interesting microstructures of isotropic cellular materials that maximize the bulk or shear modulus have been found and presented. The methodology can be extended to incorporate other material properties of interest such as designing isotropic cellular materials with negative Poisson's ratio.     

Multi-objective system reliability-based optimization method for design of a fully parametric concept car body

This article investigates multi-objective optimization under reliability constraints with applications in vehicle structural design. To improve computational efficiency, an improved multi-objective system reliability-based design optimization (MOSRBDO) method is developed, and used to explore the lightweight and high-performance design of a concept car body under uncertainty. A parametric model knowledge base is established, followed by the construction of a fully parametric concept car body of a multi-purpose vehicle (FPCCB-MPV) based on the knowledge base. The structural shape, gauge and topology optimization are then designed on the basis of FPCCB-MPV. The numerical implementation of MOSRBDO employs the double-loop method with design optimization in the outer loop and system reliability analysis in the inner loop. Multi-objective particle swarm optimization is used as the outer loop optimization solver. An improved multi-modal radial-based importance sampling (MRBIS) method is utilized as the system reliability solver for multi-constraint analysis in the inner loop. The accuracy and efficiency of the MRBIS method are demonstrated on three widely used test problems. In conclusion, MOSRBDO has been successfully applied for the design of a full parametric concept car body. The results show that the improved MOSRBDO method is more effective and efficient than the traditional MOSRBDO while achieving the same accuracy, and that the optimized body-in-white structure signifies a noticeable improvement from the baseline model.     

Modified fully utilized design (MFUD) method for stress and displacement constraints

The traditional fully stressed method performs satisfactorily for stress-limited structural design. When this method is extended to include displacement limitations in addition to stress constraints, it is known as the Fully Utilized Design (FUD). Typically, the FUD produces an overdesign, which is the primary limitation of this otherwise elegant method. We have modified FUD in an attempt to alleviate the limitation. This new method, called the Modified Fully Utilized Design (MFUD) method, has been tested successfully on a number of problems that were subjected to multiple loads and had both stress and displacement constraints. The solutions obtained with MFUD compare favourably with the optimum results that can be generated by using non-linear mathematical programming techniques. The MFUD method appears to have alleviated the overdesign condition and offers the simplicity of a direct, fully stressed type of design method that is distinctly different from optimization and optimality criteria formulations. The MFUD method is being developed for practicing engineers who favour traditional design methods rather than methods based on advanced calculus and non-linear mathematical programming techniques. The Integrated Force Method (IFM) was found to be the appropriate analysis tool in the development of the MFUD method. In this paper, the MFUD method and its optimality are examined along with a number of illustrative examples. © 1998 This paper was produced under the auspices of the U.S. Government and it is therefore not subject to copyright in the U.S.     

Compliant mechanism design with non-linear materials using topology optimization

In this paper, compliant mechanism design with non-linear materials using topology optimization is presented. A general displacement functional with non-linear material model is used in the topology optimization formulation. Sensitivity analysis of this displacement functional is derived from the adjoint method. Optimal compliant mechanism examples for maximizing the mechanical advantage are presented and the effect of non-linear material on the optimal design are considered.     

Topology optimization of continuum structures with bi-modulus materials

Since the elasticity of bi-modulus materials is stress dependent, it is difficult to apply most conventional topology optimization methods to such bi-modulus structures owing to great computational expense. Therefore, this study employs the material-replacement method to improve the computational efficiency for topology optimization of bi-modulus structures. In this method, first, the bi-modulus material is replaced by two isotropic materials which have the same tensile or compressive modulus. Secondly, the isotropic materials for finite elements are determined by the local stress/strain states. The local elemental stiffness can be modified according to the current modulus and stress state of the element. Thirdly, the relative densities of elements, acting as the design variables, are updated using the optimality criterion method. Finally, the distributions of elemental densities and moduli are obtained for further applications. Several typical numerical examples are used to demonstrate the effectiveness of the proposed method.     

Voigt–Reuss topology optimization for structures with linear elastic material behaviours

The desired results of variable topology material layout computations are stable and discrete material distributions that optimize the performance of structural systems. To achieve such material layout designs a continuous topology design framework based on hybrid combinations of classical Reuss (compliant) and Voigt (stiff) mixing rules is investigated. To avoid checkerboarding instabilities, the continuous topology optimization formulation is coupled with a novel spatial filtering procedure. The issue of obtaining globally optimal discrete layout designs with the proposed formulation is investigated using a continuation method which gradually transitions from the stiff Voigt formulation to the compliant Reuss formulation. The very good performance of the proposed methods is demonstrated on four structural topology design optimization problems from the literature. © 1997 John Wiley & sons, Ltd.     

Adaptive improved response surface method for reliability-based design optimization

Reliability-based design optimization (RBDO) requires the evaluation of probabilistic constraints (or reliability), which can be very time consuming. Therefore, a practical solution for efficient reliability analysis is needed. The response surface method (RSM) and dimension reduction (DR) are two well-known approximation methods that construct the probabilistic limit state functions for reliability analysis. This article proposes a new RSM-based approximation approach, named the adaptive improved response surface method (AIRSM), which uses the moving least-squares method in conjunction with a new weight function. AIRSM is tested with two simplified designs of experiments: saturated design and central composite design. Its performance on reliability analysis is compared with DR in terms of efficiency and accuracy in multiple RBDO test problems.     

Optimal design of material properties and material distribution for multiple loading conditions

An extension of recent work¹ on the simultaneous optimization of material and structure to address the design of structures under multiple loading conditions is presented. Material properties are represented in the most general form possible, namely, as elements of the unrestricted set of positive-semi-definite constitutive tensors of a linearly elastic continuum. Existence of solutions can be shown when the objective is a weighted average of compliances and a resource constraint measured as the 2-norm or the trace of the constitutive tensors is included. The optimized material properties can be derived analytically. The optimization of the layout of the material leads to a sizing problem of structural optimization involving a non-linear, non-smooth elasticity analysis. The computational solution of this problem is discussed and illustrated with examples.     

The boundary contour method for two-dimensional Stokes flow and incompressible elastic materials

 A variant of the boundary element method, called the boundary contour method (BCM), offers a further reduction in dimensionality. Consequently, boundary contour analysis of two-dimensional (2-D) problems does not require any numerical integration at all. While the method has enjoyed many successful applications in linear elasticity, the above advantage has not been exploited for Stokes flow problems and incompressible media. In order to extend the BCM to these materials, this paper presents a development of the method based on the equations of Stokes flow and its 2-D kernel tensors. Potential functions are derived for quadratic boundary elements. Numerical solutions for some well-known examples are compared with the analytical ones to validate the development. Received 28 August 2001 / Accepted 15 January 2002     

Applications of thermoelastic stress analysis to composite materials

A number of applied thermoelastic stress analysis (TSA) studies on composite components and assemblies are described, for the purpose of illustrating the potential of the technique for use with composite materials.