An enhanced genetic algorithm for structural topology optimization

Genetic algorithms (GAs) have become a popular optimization tool for many areas of research and topology optimization an effective design tool for obtaining efficient and lighter structures. In this paper, a versatile, robust and enhanced GA is proposed for structural topology optimization by using problem‐specific knowledge. The original discrete black‐and‐white (0–1) problem is directly solved by using a bit‐array representation method. To address the related pronounced connectivity issue effectively, the four‐neighbourhood connectivity is used to suppress the occurrence of checkerboard patterns. A simpler version of the perimeter control approach is developed to obtain a well‐posed problem and the total number of hinges of each individual is explicitly penalized to achieve a hinge‐free design. To handle the problem of representation degeneracy effectively, a recessive gene technique is applied to viable topologies while unusable topologies are penalized in a hierarchical manner. An efficient FEM‐based function evaluation method is developed to reduce the computational cost. A dynamic penalty method is presented for the GA to convert the constrained optimization problem into an unconstrained problem without the possible degeneracy. With all these enhancements and appropriate choice of the GA operators, the present GA can achieve significant improvements in evolving into near‐optimum solutions and viable topologies with checkerboard free, mesh independent and hinge‐free characteristics. Numerical results show that the present GA can be more efficient and robust than the conventional GAs in solving the structural topology optimization problems of minimum compliance design, minimum weight design and optimal compliant mechanisms design. It is suggested that the present enhanced GA using problem‐specific knowledge can be a powerful global search tool for structural topology optimization. Copyright © 2005 John Wiley & Sons, Ltd.     

A method for selecting macro-scale structures with axially loaded members

This paper presents a method to support the selection of lightweight large-scale structures. The method enables the ranking of alternative structural forms, whose axially loaded members can resist to either instability failure or material yield. Unlike previous approaches for concept design, this work models buckling failure to assess the interaction between the choice of a structural form and the choice of the cross-section shapes of its constituents. Shape transformers and scaling factors are introduced to characterize the structural efficiency of alternative cross-sectional shapes. Such parameters are dimensionless and enable to measure the shape efficiency without specifying the details of the cross-section geometry. The approach eases optimization at the concept design stage and it permits to assess how the selection of the member cross-sections impacts the lightweight potential of the structural topology. The model is used to construct charts for optimizing and selecting alternative forms. The method is applied in an industrial setting in order to compare three different structural concepts for a particular design application. The case study identified the potential performance of three structural forms and gave insight into the selection of the parameters that most influence structural performance.     

Evolutionary topology and shape design for general physical field problems

 As a practical tool for design engineers, evolutionary techniques for structural topology, shape and size optimisation have successfully resolved the whole range of structural problems from frames to 2D and 3D continuums with design criteria of stress, stiffness, frequency and buckling. In view of the generality of the finite element formulation using either a variational calculus or weighted residual approach, it is logical to extend its applications to other steady state field problems in mathematical physics governed by partial differential equations. The range of physical problems falling to this category includes heat conduction, incompressible fluid flow, elastic torsion, electrostatics and magnetostatics, etc. This paper discusses the general principles involved in setting up the adaptive evolutionary algorithms that have finite element techniques as the analysis engines. To avoid the complexity of classical solutions, the proposed method develops a simple outer loop procedure consisting of finite element analysis and design modifications. Illustrative examples are presented to demonstrate the capability in solving the above-mentioned physical field situations.     

Optimum Design of Composite Sandwich Structures Subjected to Combined Torsion and Bending Loads

This research is motivated by the increase use of composite sandwich structures in a wide range of industries such as automotive, aerospace and civil infrastructure. To maximise stiffness at minimum weight, the paper develops a minimum weight optimization method for sandwich structure under combined torsion and bending loads. We first extend the minimum-weight design of sandwich structures under bending load to the case of torsional deformation and then present optimum solutions for the combined requirements of both bending and torsional stiffness. Three design cases are identified for a sandwich structure required to meet multiple design constraints of torsion and bending stiffness. The optimum solutions for all three cases are derived. To illustrate the newly developed optimum design solutions, numerical examples are presented for sandwich structures made of either isotropic face skins or orthotropic composite face skins.     

基于遗传算法的离散型结构拓扑优化设计

采用遗传算法求解包括桁架结构和框架结构的离散型结构拓扑优化问题。在遗传算法的基础上,通过引入拓扑变量并修改被删除杆件的材料弹性模量,提出了一个受多工况荷载作用,能同时考虑应力、稳定及位移等约束的离散型结构拓扑优化问题统一数学模型。该模型不但能同时适用于桁架结构和框架结构等离散型结构拓扑优化问题,而且还能解决奇异最优解问题。结合上述统一数学模型和遗传算法,给出了求解离散型结构拓扑优化问题的优化方法。算例结果表明,采用该文提出的拓扑优化方法可有效、方便地对桁架结构、框架结构等离散型结构进行拓扑优化设计。     

An analytical solution for the large deflections of a slender sandwich beam with a metallic foam core under transverse loading by a flat punch

The large deflections of slender ultralight sandwich beams with a metallic foam core are studied under transverse loading by a flat punch, in which interaction of bending and stretching induced by large deflections is considered. Firstly, a unified yield criterion for metallic sandwich structures considering the effect of core strength is proposed, which is valid for metallic sandwich cross-sections with various core strengths and geometries. This can reduce to the yield criterion for a solid monolithic cross-section and the classical yield criterion for sandwich cross-sections with a weak core, respectively. Then, analytical solutions for the large deflections of fully clamped and simply supported metallic foam core sandwich beams are derived under transverse loading by a flat punch, respectively. Comparisons of the present solutions with experimental results are presented and good agreements are found. The effects of the core strength, the size of loading punch and the boundary conditions on the structural response of sandwich beams are discussed in detail. It is shown that the axial stretching induced by large deflections has significant effect on the load-carrying and energy absorption capacities of sandwich structures in the post-yield regime, and the load-carrying and plastic energy absorption capacities of metallic foam core sandwich beams may be underestimated as the core strength is neglected in analysis, especially for the sandwich beams with a strong core.     

Stress analysis of multi-layered hollow anisotropic composite cylindrical structures using the homogenization method

This paper presents a general and efficient stress analysis strategy for hollow composite cylindrical structures consisting of multiple layers of different anisotropic materials subjected to different loads. Cylindrical material anisotropy and various loading conditions are considered in the stress analysis. The general stress solutions for homogenized hollow anisotropic cylinders subjected to pressure, axial force, torsion, shear and bending are presented with explicit formulations under typical force and displacement boundary conditions. The stresses and strains in a layer of the composite cylindrical structures are obtained from the solutions of homogenized hollow cylinders with effective material properties and discontinuous layer material properties. Effective axial, torsional, bending and coupling stiffness coefficients taking into account material anisotropy are also determined from the strain solutions for the hollow composite cylindrical structures. Examples show that the material anisotropy may have significant effects on the effective stiffness coefficients in some cases. The stress analysis method is demonstrated with an example of stress analysis of a 22-layer composite riser, and the results are compared with numerical solutions. This method is efficient for stress analysis of thin-walled or moderately thick-walled hollow composite cylindrical structures with various multiple layers of different materials or arbitrary fiber angles because no explicit interfacial continuity parameters are required. It provides an efficient and easy-to-use analysis tool for assessing hollow composite cylindrical structures in engineering applications.     

模糊参数平面连续体结构的拓扑优化设计

研究了具有模糊参数的连续体结构在模糊载荷作用下的拓扑优化设计问题。利用信息熵将模糊变量转换为随机变量,构建了随机载荷作用下的随机参数的连续体结构的拓扑优化设计数学模型,以结构的形状拓扑信息为设计变量,结构总质量均值极小化为目标函数,满足单元应力可靠性为约束条件,利用分布函数法对应力可靠性约束进行了等价显式化处理。基于随机因子法,利用代数综合法导出了应力响应的数字特征的计算表达式。采用双方向渐进结构优化(BESO)方法求解。通过两个算例验证了该文模型及求解方法的合理性和有效性。     

PREDICTION OF BENDING FATIGUE BEHAVIOUR BY THE REFERENCE STRESS APPROACH

Abstract— A technique is presented for prediction of low-cycle fatigue behaviour under bending conditions from the knowledge of uniaxial fatigue data. The technique utilizes the reference stress approach used in the analysis of creeping components. The results enable determination of nominal elastic bending stress in terms of the observed saturation stress amplitude in an uniaxial fatigue test conducted at a reference value of strain amplitude. The reference parameters are determined for beams with both rectangular and circular cross-sections. The predictions of fatigue bending behaviour are in excellent agreement with closed form solutions reported recently. The merits of this alternative approach lie in its potential applicability to other structural situations once their reference uniaxial parameters are determined. Since the reference parameters are nearly the same for both creep and fatigue, the approach can be a useful experimental tool for relating creep-fatigue interaction effects in structural components with uniaxial creep-fatigue tests conducted under the reference conditions.     

随机参数平面连续体结构的频率拓扑优化设计

摘 要 研究几何和物理参数均为随机变量的平面连续体结构在结构基频约束下的拓扑优化设计问题。以结构总质量均值极小化为目标函数,以结构的形状拓扑信息为设计变量,以结构基频概率可靠性指标为约束条件,构建了随机结构拓扑优化设计数学模型。利用代数综合法,导出了随机参数结构动力响应的均值和均方差的计算表达式。采用渐进结构优化的求解策略与方法,通过两个算例验证了文中模型及求解方法的合理性和可行性。     

基于近场动力学微分算子的变截面梁动力特性分析方法EI北大核心CSCD

变截面梁式构件广泛应用于工程结构中,其动力特性更是结构设计和状态评估中的重要考虑因素之一。基于新兴的近场动力学微分算子(Peridynamic differential operator,PDDO),尝试提出了一种用于变截面梁动力特性分析的非局部方法。将变截面梁的动力学微分控制方程与边界条件通过PDDO由局部微分形式转化为对应的非局部积分形式,再结合拉格朗日乘数法与变分原理,将非局部积分形式的控制方程与边界条件转化为标准特征值问题表达形式,从而求得自振频率与振型。通过对等截面梁的自由振动分析并与解析解对比,验证了该方法良好的收敛性与准确性。进一步通过求解下边界一次、二次变化的连续变截面梁,证明了该方法对于任意变截面梁自由振动分析的适用性与可靠性。开展含孔变截面梁的自由振动分析,体现了该文的非局部方法在含缺陷构件振动分析和损伤识别问题方面的潜力,可为含缺陷变截面构件的动力分析问题提供新思路。     

Fatigue crack growth of a welded tube–flange connection under bending and torsional loading

In this contribution the results of an experimental investigation into the fatigue crack growth of welded tube-to-plate specimens of steel StE 460 under bending, torsion, and combined in-phase and out-of-phase bending/torsion loading are presented. The tests were performed at stress ratios of R = −1 and R = 0. The residual stresses were reduced by thermal stress relief. The fatigue crack development is compared with the prediction on the crack growth rates of Paris. Individual stress intensity factors for the semielliptical surface cracks in the tube-flange specimens are approximated on a weight function analogy using the published solutions of other workers.     

任意非对称断面薄壁箱梁一维有限元分析

根据薄壁箱梁的实际支承特点,设置支承坐标系并在支承坐标系中建立变形协调的相容条件,针对任意非对称断面薄壁箱梁,导出了考虑拉(压)弯扭翘空间耦合分析的单元刚度矩阵及等效节点力公式。此外,提出了通过设置具有线刚度、转动刚度、扭翘刚度的假想弹簧单元,对薄壁箱梁的复杂约束条件进行处理的一般方法。所得到的刚度矩阵表明,只有当忽略翘曲变形对截面转角的影响时,轴向拉压才只与水平弯曲及竖向弯曲相耦合,而与约束扭转不再耦合。算例结果表明了分析方法的有效性。     

Stress intensity factors for circumferential through‐wall cracks in thin‐walled cylindrical shells subjected to tension and torsion

In order to assess the structural integrity of tubular members or pipes containing circumferential through‐wall cracks, their stress intensity factor solutions are required. While stress intensity factors for tension and bending are available, few solutions exist for the case of torsion, even though these components may also be subjected to torque. In this paper, the finite element method is used to compute the stress intensity factors for this geometry under tension and torsion. Shell elements are employed to compute the results for thin shells by the means of the displacement extrapolation technique. The computed results indicate that the available analytical solution for torsional loading, which is based on shallow shell theory, is nonconservative for long cracks in thin shells. Shallow shell theory is in general not applicable to long cracks, and the present work is therefore able to provide solutions for a wider range of crack lengths than what is currently available.     

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。     

The effect of steady torsion on fatigue crack growth in shafts

Most of catastrophic mechanical failures in power rotor shafts occur under cyclic bending combined with steady torsion: Mode I (ΔK_I) combined with Mode III (K_III). An analysis of the influence of steady torsion loading on fatigue crack growth rates in shafts is presented for short as well as long cracks. Long cracks growth tests have been carried out on cylindrical specimens in DIN Ck45k steel for two types of testing: rotary or alternating bending combined with steady torsion in order to simulate real conditions on power rotor shafts. The growth and shape evolution of semi-elliptical surface cracks, starting from the cylindrical specimen surface, has been measured for several loading conditions and both testing types. Short crack growth tests have been carried out on specimens of the same material DIN Ck45k, under alternating bending combined with steady torsion. The short crack growth rates obtained are compared with long crack growth rates. Results have shown a significant reduction of the crack growth rates when a steady torsion Mode III is superimposed to cyclic Mode I. A 3D Finite Element analysis has also shown that Stress Intensity Factor values at the corner crack surface depend on the steady torsion value and the direction of the applied torque.     

Fatigue analysis of unidirectional GFRP composites under combined bending and torsional loads

Fatigue behavior of unidirectional glass fiber reinforced polyester (GFRP) composites at room temperature under in-phase combined torsion/bending loading was investigated. All fatigue tests were carried out on constant-deflection fatigue machine with frequency of 25 Hz. A 30% reduction from the initial applied moments was taken as a failure criterion in the combined torsion/bending fatigue tests of the composite materials. A series of pure torsional fatigue tests were conducted to construct the failure contour of GFRP composites using different failure theories. The obtained S–N curves from combined torsion/bending tests were compared with both, pure torsion fatigue test results and published results of pure bending fatigue tests of GFRP rods. Pictures by scanning electron microscope were used to closely examine the failure mode of the tested specimens under combined torsion/bending loading.

The results showed that, the unidirectional glass fiber reinforced polyester composites have poor torsional fatigue strength compared with the published results of pure bending fatigue strength. Endurance limit value (calculated from S–N equation at N = 10⁷ cycles) of GFRP specimens tested under combined torsion/bending loading equals 8.5 times the endurance limit of pure torsion fatigue. On the other hand the endurance limit of combined torsion/bending fatigue strength approximately half the fatigue limit of pure bending fatigue strength. The predicted values of combined torsion/bending fatigue strength at different number of cycles, using the published failure theory are in good agreement with the experimental data. For the investigated range of fiber volume fractions (V_f) it was found that higher stress levels are needed to produce fatigue failure after the same number of cycles as V_f increases.     

桁架结构智能布局优化设计

结构的布局优化由于涉及尺寸、形状和拓扑三个层次的综合设计而成为优化问题中的难点,结合桁架结构提出了一个基于多个初始基结构的布局优化方法。以智能生成的、型式多样合理的基结构代替传统模型中的单一基结构,然后从不同基结构下的拓扑优化结果中找出最优设计。在克服传统基结构法有可能限制求解空间而丢失最优解这一局限性的同时,将形状和拓扑优化设计有效分离,降低了求解的难度,并且结合拓扑变化法,实现了桁架结构从选型生成、分析计算到优化设计的一体化智能设计过程。算例表明:利用该文提出的方法进行桁架结构的最优布局设计是可靠有效的。     

Application of an energy model for fatigue life prediction of construction steels under bending, torsion and synchronous bending and torsion

The paper contains a mathematical model of the material’s behaviour under cyclic loading taking into account the dynamics of the fatigue process, including the number of cycles to failure, induced by the mean stress value. The coefficients in the proposed model have been obtained from experimental tests under symmetrical and nonsymmetrical loading (with the stress ratio R=0). The proposed model has been used in order to modify an energy criterion with the aim of accounting for the influence of the mean stress on the fatigue life. The fatigue tests have been performed for structural steels 10HNAP and 18G2A subjected to cyclic bending, torsion and synchronous bending with torsion, by considering different values of the mean stress. A good agreement between the calculated and experimental results has been obtained.     

Effect of steady torsion on fatigue crack initiation and propagation under rotating bending: Multiaxial fatigue and mixed-mode cracking

Axles and shafts are of prime importance concerning safety in transportation industry and railway in particular. Knowledge of fatigue crack growth under typical loading conditions of axles and shafts with rotating bending and steady torsion is therefore essential for design and maintenance purposes. The effect of a steady torsion on both small and long crack growth under rotating bending is focused in this paper. For small crack growth, a modified effective strain-based intensity factor range is proposed as the parameter that correlates small fatigue crack growth data under proportional or non-proportional multiaxial loading conditions. Results show that this parameter is appropriate for determining fatigue crack growth of small cracks on rotating bending with an imposed steady torsion.