A level set method for shape and topology optimization of large‐displacement compliant mechanisms

A parameterization level set method is presented for structural shape and topology optimization of compliant mechanisms involving large displacements. A level set model is established mathematically as the Hamilton–Jacobi equation to capture the motion of the free boundary of a continuum structure. The structural design boundary is thus described implicitly as the zero level set of a level set scalar function of higher dimension. The radial basis function with compact support is then applied to interpolate the level set function, leading to a relaxation and separation of the temporal and spatial discretizations related to the original partial differential equation. In doing so, the more difficult shape and topology optimization problem is now fully parameterized into a relatively easier size optimization of generalized expansion coefficients. As a result, the optimization is changed into a numerical process of implementing a series of motions of the implicit level set function via an existing efficient convex programming method. With the concept of the shape derivative, the geometrical non‐linearity is included in the rigorous design sensitivity analysis to appropriately capture the large displacements of compliant mechanisms. Several numerical benchmark examples illustrate the effectiveness of the present level set method, in particular, its capability of generating new holes inside the material domain. The proposed method not only retains the favorable features of the implicit free boundary representation but also overcomes several unfavorable numerical considerations relevant to the explicit scheme, the reinitialization procedure, and the velocity extension algorithm in the conventional level set method. Copyright © 2008 John Wiley & Sons, Ltd.     

基于分段常数水平集方法的声振耦合系统拓扑优化

针对结构与无限大声场的声振耦合系统中结构的双材料拓扑优化问题进行了研究。采用有限元与边界元方法分别对结构和声场进行离散。基于分段常数水平集(piecewise constant level set,PCLS)方法,构造了结构的刚度阵、质量阵与阻尼阵。优化目标选为最小化结构指定位置的振幅平方,采用伴随变量法进行灵敏度分析。引入二次罚函数方法来实现体积约束,基于灵敏度信息对优化参数进行重新定义,克服了参数的问题依赖性。数值结果表明优化设计可以显著降低结构的振幅,证实了优化方法的有效性。不同算例下体积约束在相同优化参数下均得到很好满足,说明了重新定义参数的优越性。     

Continuum structural topological optimizations with stress constraints based on an active constraint technique

Stress‐related problems have not been given the same attention as the minimum compliance topological optimization problem in the literature. Continuum structural topological optimization with stress constraints is of wide engineering application prospect, in which there still are many problems to solve, such as the stress concentration, an equivalent approximate optimization model and etc. A new and effective topological optimization method of continuum structures with the stress constraints and the objective function being the structural volume has been presented in this paper. To solve the stress concentration issue, an approximate stress gradient evaluation for any element is introduced, and a total aggregation normalized stress gradient constraint is constructed for the optimized structure under the r?th load case. To obtain stable convergent series solutions and enhance the control on the stress level, two p‐norm global stress constraint functions with different indexes are adopted, and some weighting p‐norm global stress constraint functions are introduced for any load case. And an equivalent topological optimization model with reduced stress constraints is constructed,being incorporated with the rational approximation for material properties, an active constraint technique, a trust region scheme, and an effective local stress approach like the qp approach to resolve the stress singularity phenomenon. Hence, a set of stress quadratic explicit approximations are constructed, based on stress sensitivities and the method of moving asymptotes. A set of algorithm for the one level optimization problem with artificial variables and many possible non‐active design variables is proposed by adopting an inequality constrained nonlinear programming method with simple trust regions, based on the primal‐dual theory, in which the non‐smooth expressions of the design variable solutions are reformulated as smoothing functions of the Lagrange multipliers by using a novel smoothing function. Finally, a two‐level optimization design scheme with active constraint technique, i.e. varied constraint limits, is proposed to deal with the aggregation constraints that always are of loose constraint (non active constraint) features in the conventional structural optimization method. A novel structural topological optimization method with stress constraints and its algorithm are formed, and examples are provided to demonstrate that the proposed method is feasible and very effective. © 2016 The Authors. International Journal for Numerical Methods in Engineering published by John Wiley & Sons Ltd.     

导管架海洋平台结构模糊优化设计

考虑约束条件边界的模糊性,建立了导管架海洋平台结构模糊优化设计模型。对模糊优化模型中的设计变量、目标函数和约束条件进行了模糊处理。针对导管架海洋平台的特点,用模糊优选法确定约束条件边界容差系数,由界限搜索法求解模糊约束集和模糊目标集之交集的最优水平截集*l,进而求得模糊优化问题的最优解。以胜利油田埕北11#井采油平台为例进行了模糊优化设计,并与确定性优化设计相比较,分析了两种优化设计中设计变量的走向及原因,算例结果还显示目标函数值比确定性优化设计值有较大幅度下降,说明考虑模糊因素进行优化设计的可行性和科学性。     

Structural shape and topology optimization of cast parts using level set method

This paper presents a level set‐based shape and topology optimization method for conceptual design of cast parts. In order to be successfully manufactured by the casting process, the geometry of cast parts should satisfy certain moldability conditions, which poses additional constraints in the shape and topology optimization of cast parts. Instead of using the originally point‐wise constraint statement, we propose a casting constraint in the form of domain integration over a narrowband near the material boundaries. This constraint is expressed in terms of the gradient of the level set function defining the structural shape and topology. Its explicit and analytical form facilitates the sensitivity analysis and numerical implementation. As compared with the standard implementation of the level set method based on the steepest descent algorithm, the proposed method uses velocity field design variables and combines the level set method with the gradient‐based mathematical programming algorithm on the basis of the derived sensitivity scheme of the objective function and the constraints. This approach is able to simultaneously account for the casting constraint and the conventional material volume constraint in a convenient way. In this method, the optimization process can be started from an arbitrary initial design, without the need for an initial design satisfying the cast constraint. Numerical examples in both 2D and 3D design domain are given to demonstrate the validity and effectiveness of the proposed method. Copyright © 2017 John Wiley & Sons, Ltd.     

Structural shape and topology optimization using a meshless Galerkin level set method

This paper aims to propose a meshless Galerkin level set method for shape and topology optimization of continuum structures. To take advantage of the implicit free boundary representation scheme, the design boundary is represented as the zero level set of a scalar level set function, to flexibly handle complex shape fidelity and topology changes by maintaining concise and smooth interface. Compactly supported radial basis functions (CSRBFs) are used to parameterize the level set function and construct the shape functions for meshfree approximations based on a set of unstructured field nodes. The meshless Galerkin method with global weak form is used to implement the discretization of the state equations. This provides a pathway to unify the two different numerical stages in most conventional level set methods: (1) the propagation of discrete level set function on a set of Eulerian grid and (2) the approximation of discrete equations on a set of Lagrangian mesh. The original more difficult shape and topology optimization based on the level set equation is transformed into a relatively easier size optimization, to which many efficient optimization algorithms can be applied. The proposed level set method can describe the moving boundaries without remeshing for discontinuities. The motion of the free boundary is just a question of advancing the discrete level set function in time by solving the size optimization. Several benchmark examples are used to demonstrate the effectiveness of the proposed method. The numerical results show that the proposed method can simplify numerical process and avoid numerical difficulties involved in most conventional level set methods. It is straightforward to apply the proposed method to more advanced shape and topology optimization problems. Copyright © 2011 John Wiley & Sons, Ltd.     

基于响应面法对桁架结构形状的优化设计

针对数学非线性回归问题,需不断改进设计模型和设计参数,从而使得设计效果达到最佳。求解约束条件下体积最小问题时经常用响应面法进行优化,即利用函数关系拟合仿真模型,采用筛选试验来确定优化方向。为了优化经典10杆桁架结构的形状,基于响应面法,编写并运行APDL（ANSYS parametric design language,参数化设计语言）程序,得到各桁架的初始应力和体积。以节点纵坐标值的改变来反映形状的变化,各因子设置三水平并编码为-1,0,1,通过响应面法（response surface method,RSM）进行寻优并调整中心点和水平。基于调整后的水平,先找到最佳邻域,再用优化软件在最佳邻域内求解桁架在许应力下体积的最优解,最后将确定好的节点纵坐标值回代到APDL程序中验证是否满足约束条件,若满足,则此时的体积为最优解。结果表明：利用响应面法优化桁架杆的迭代次数仅为3次,它能快速定位最优解,降低了前期设计成本。通过对比文献[9]可知响应面法对结构的形状优化更为有效,能快速定位出设计试验方案,在工程应用中对于寻找在约束条件下的最佳配比设计有着高效性。     

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.     

Fuzzy Optimization of an Elevator Mechanism Applying the Genetic Algorithm and Neural Networks

1Introduction Wormgearingisoftenappliedforpowertransmissioninanelevatormechanismbecauseitgivesa greatreductioninrelativespeedandalargeincreaseineffectivepower.Soastoeconomizethenon ferrousmetalofthetoothcoronaofawormgear,itisveryimportanttoadoptoptimizationmethodsto designthewormgearing.2Principleofthegeneticalgorithm Thegeneticalgorithm[1]isamethodforsolvingoptimizationproblemsthatisbasedonnaturalselec tion,theprocessthatdrivesbiologicalevolution.Thegeneticalgorithmrepeatedlymodifiesapopu la…     

Solution to the topology optimization problem using a time-evolution equation

This article describes a numerical solution to the topology optimization problem using a time-evolution equation. The design variables of the topology optimization problem are defined as a mathematical scalar function in a given design domain. The scalar function is projected to the normalized density function. The adjoint variable method is used to determine the gradient defined as the ratio of the variation of the objective function or constraint function to the variation of the design variable. The variation of design variables is obtained using the solution of the time-evolution equation in which the source term and Neumann boundary condition are given as a negative gradient. The distribution of design variables yielding an optimal solution is obtained by time integration of the solution of the time-evolution equation. By solving the topology optimization problem using the proposed method, it is shown that the objective function decreases when the constraints are satisfied. Furthermore, we apply the proposed method to the thermal resistance minimization problem under the total volume constraint and the mean compliance minimization problem under the total volume constraint.     

Topology optimization in Bernoulli free boundary problems

In this work we consider the topology optimization of systems governed by the external Bernoulli free boundary problem arising, for example, from the mathematical modelling of electro-chemical machining. In this work we combine, for the first time, the so-called pseudo-solid approach to the solution of governing free boundary problems and the level set method, which is used to define the design domain. Previous studies of the problem showed a tendency towards topological changes in the design, which can now automatically take place thanks to level set parametrization. The scalar function used in the level set method is parametrized using radial basis functions, converting the problem into a parametric optimization problem, which is solved using a gradient-based method.     

约束阻尼板结构振动声辐射优化

根据经典薄板理论,建立约束阻尼板有限元模型,将其视作镶嵌于无限大刚性障板,利用Rayleigh积分法推导结构的辐射声功率及灵敏度表达式。以一阶峰值频率或频带激励下的声功率最小化为目标,约束阻尼材料体积分数为约束条件,建立拓扑优化模型,采用渐进优化算法,编制了优化计算程序,获得了约束阻尼材料的最优拓扑构型,并与全覆盖板及基板的辐射声功率进行了对比。研究表明：以声功率最小化为目标,对约束阻尼材料布局进行拓扑优化,能有效抑制结构的振动声辐射,为结构低噪声设计提供了重要的理论参考和技术手段。     

Shape optimization using time evolution equations

In this study, we deal with a numerical solution based on time evolution equations to solve the optimization problem for finding the shape that minimizes the objective function under given constraints. The design variables of the shape optimization problem are defined on a given original domain on which the boundary value problems of partial differential equations are defined. The variations of the domain are obtained by the time integration of the solution to derive the time evolution equations defined in the original domain. The shape gradient with respect to the domain variations are given as the Neumann boundary condition defined on the original domain boundary. When the constraints are satisfied, the decreasing property of the objective function is guaranteed by the proposed method. Furthermore, the proposed method is used to minimize the heat resistance under a total volume constraint and to solve the minimization problem of mean compliance under a total volume constraint.     

水下耐压结构拓扑优化设计方法探究

探究了拓扑优化设计方法在水下耐压结构设计中的应用。与固定载荷作用下结构的优化设计相比,此类问题需要正确地确定压力作用面。在拓扑优化过程中,利用变密度法得到的中间结构拓扑实际上可以看成是灰度图。基于此,提出了基于图像分割技术的压力加载面搜索方法,并利用距离正规化水平集方法(DRLSE)检测图像边界。利用数值算例验证了方法的有效性,并研究了静水压力作用下结构的拓扑优化设计问题。在给定材料约束的前提下,研究了不同边界条件下耐压壳体的最小柔顺度及最优结构拓扑形式。优化结果说明了该方法在多球交接耐压壳结构形式优化设计及复杂边界条件下耐压结构新形式探索中的工程应用价值。     

A move limit strategy for level set based structural optimization

A move limit strategy is proposed for level set based structural optimization, which offers a tool to restrict the allowable change of the free boundary of a structure in each iterative step of optimization. To realize the move limit strategy, a function for modifying the extended design velocity is proposed. Application of the move limit strategy is demonstrated by several numerical examples of 2D structures. The results show that the move limit strategy is helpful to improve the stability and convergence rate of level set based structural optimization.     

周期性多材料结构稳态热传导拓扑优化设计

提出一种考虑周期性约束的多材料结构稳态热传导拓扑优化设计方法。针对多材料结构,提出基于有序有理近似材料属性模型（ordered rational approximation of material properties,Ordered-RAMP）的多材料插值模型。以结构散热弱度最小化为目标函数,体积为约束条件,将设计区域划分为有限个相同的子多材料区域。通过重新分配单元散热弱度基值,实现周期性几何约束,借助优化准则法推导设计变量的迭代格式。通过典型2D与3D数值算例,分析不同子区域个数对宏观结构与微观子区域多材料拓扑构型的影响。结果表明:所提方法可实现面向多材料结构的周期性微观构型设计,且各材料分布合理边界清晰,具有良好的稳健性;当子区域个数不同时,均可得到具有周期性的拓扑构型,且所获拓扑形式具有差异性。     

胶印机滚筒结构的拓扑及尺寸优化设计

胶印机滚筒在印刷压力作用下的挠曲变形是影响印品质量的重要原因。以PZ1740胶印机橡皮滚筒为研究对象,提出了一种基于拓扑优化和尺寸优化的橡皮滚筒结构设计方法。建立了滚筒结构的二维拓扑模型,以应变能最小为目标,体积分数作为约束,得到滚筒结构的拓扑分布;在拓扑构型基础上,建立了滚筒结构的参数化模型,以挠曲变形最小为目标,结构质量作为约束条件进行尺寸优化,得到了滚筒具体的结构。优化分析结果表明,优化后的滚筒结构在质量约束的条件下有效地减小了挠曲变形,提出的方法在胶印机滚筒结构优化设计中可行且有效。     

A consistent grayscale‐free topology optimization method using the level‐set method and zero‐level boundary tracking mesh

This paper proposes a level‐set based topology optimization method incorporating a boundary tracking mesh generating method and nonlinear programming. Because the boundary tracking mesh is always conformed to the structural boundary, good approximation to the boundary is maintained during optimization; therefore, structural design problems are solved completely without grayscale material. Previously, we introduced the boundary tracking mesh generating method into level‐set based topology optimization and updated the design variables by solving the level‐set equation. In order to adapt our previous method to general structural optimization frameworks, the incorporation of the method with nonlinear programming is investigated in this paper. To successfully incorporate nonlinear programming, the optimization problem is regularized using a double‐well potential. Furthermore, the sensitivities with respect to the design variables are strictly derived to maintain consistency in mathematical programming. We expect the investigation to open up a new class of grayscale‐free topology optimization. The usefulness of the proposed method is demonstrated using several numerical examples targeting two‐dimensional compliant mechanism and metallic waveguide design problems. Copyright © 2014 John Wiley & Sons, Ltd.     

稳态热传导结构非概率可靠性拓扑优化设计

研究具有区间参数的稳态热传导结构在散热弱度非概率可靠性约束下的拓扑优化设计问题。建立了以单元相对导热系数为设计变量,导热材料体积极小化为目标函数,满足散热弱度非概率可靠性为约束条件的稳态热传导结构的拓扑优化设计数学模型。基于区间因子法,推导出散热弱度的均值及离差的计算表达式。采用渐进结构优化法的求解策略与方法,并利用过滤技术消除优化过程中的数值不稳定性现象。通过算例验证文中模型及求解策略、方法的合理性和有效性。