A new level set method for topology optimization of distributed compliant mechanisms

A new level set method for topology optimization of distributed compliant mechanism is presented in this study. By taking two types of mean compliance into consideration, several new objective functions are developed and built in the conventional level set method to avoid generating the de facto hinges in the created mechanisms. Aimed at eliminating the costly reinitialization procedure during the evolution of the level set function, an accelerated level set evolution algorithm is developed by adding an extra energy function, which can force the level set function to close to a signed distance function during the evolution. Two widely studied numerical examples in topology optimization of compliant mechanisms are studied to demonstrate the effectiveness of the proposed method. Copyright © 2012 John Wiley & Sons, Ltd.     

Piecewise constant level set method for structural topology optimization

In this paper, a piecewise constant level set (PCLS) method is implemented to solve a structural shape and topology optimization problem. In the classical level set method, the geometrical boundary of the structure under optimization is represented by the zero level set of a continuous level set function, e.g. the signed distance function. Instead, in the PCLS approach the boundary is described by discontinuities of PCLS functions. The PCLS method is related to the phase‐field methods, and the topology optimization problem is defined as a minimization problem with piecewise constant constraints, without the need of solving the Hamilton–Jacobi equation. The result is not moving the boundaries during the iterative procedure. Thus, it offers some advantages in treating geometries, eliminating the reinitialization and naturally nucleating holes when needed. In the paper, the PCLS method is implemented with the additive operator splitting numerical scheme, and several numerical and procedural issues of the implementation are discussed. Examples of 2D structural topology optimization problem of minimum compliance design are presented, illustrating the effectiveness of the proposed method. Copyright © 2008 John Wiley & Sons, Ltd.     

A new hole insertion method for level set based structural topology optimization

Structural shape and topology optimization using level set functions is becoming increasingly popular. However, traditional methods do not naturally allow for new hole creation and solutions can be dependent on the initial design. Various methods have been proposed that enable new hole insertion; however, the link between hole insertion and boundary optimization can be unclear. The new method presented in this paper utilizes a secondary level set function that represents a pseudo third dimension in two‐dimensional problems to facilitate new hole insertion. The update of the secondary function is connected to the primary level set function forming a meaningful link between boundary optimization and hole creation. The performance of the method is investigated to identify suitable parameters that produce good solutions for a range of problems. Copyright © 2012 John Wiley & Sons, Ltd.     

Adaptive moving mesh level set method for structure topology optimization

The level set method is a promising approach to provide flexibility in dealing with topological changes during structural optimization. Normally, the level set surface, which depicts a structure's topology by a level contour set of a continuous scalar function embedded in space, is interpolated on a fixed mesh. The accuracy of the boundary positions is therefore largely dependent on the mesh density, a characteristic of any Eulerian expression when using a fixed mesh. This article combines the adaptive moving mesh method with a level set structure topology optimization method. The finite element mesh automatically maintains a high nodal density around the structural boundaries of the material domain, whereas the mesh topology remains unchanged. Numerical experiments demonstrate the effect of the combination of a Lagrangian expression for a moving mesh and a Eulerian expression for capturing the moving boundaries.     

Bi-directional evolutionary topology optimization for designing a neutrally buoyant underwater glider

An underwater glider is a type of autonomous profiling instrument platform used for gathering data to explore the ocean. Having a neutrally buoyant glider hull is one way to improve the glider's endurance with a passive compensation for buoyancy change. This article applies the bi-directional evolutionary structural optimization (BESO) method to the optimization of an underwater glider hull, based on two materials. Firstly, the method for determining the glider's neutral buoyancy is carried out. Secondly, the optimization problem is defined and the optimization procedure is presented. In the BESO procedure, the original design area elements with low strain energy are iteratively switched from high-value materials to low-value materials until a prescribed fraction is reached. Finally, an optimal underwater glider design is generated and the result demonstrates a reasonable material distribution of the neutrally buoyant glider hull. A 26.4% buoyancy adjustment is achieved and the mass of the glider is decreased by 31%.     

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.     

Radial basis functions and level set method for structural topology optimization

Level set methods have become an attractive design tool in shape and topology optimization for obtaining lighter and more efficient structures. In this paper, the popular radial basis functions (RBFs) in scattered data fitting and function approximation are incorporated into the conventional level set methods to construct a more efficient approach for structural topology optimization. RBF implicit modelling with multiquadric (MQ) splines is developed to define the implicit level set function with a high level of accuracy and smoothness. A RBF–level set optimization method is proposed to transform the Hamilton–Jacobi partial differential equation (PDE) into a system of ordinary differential equations (ODEs) over the entire design domain by using a collocation formulation of the method of lines. With the mathematical convenience, the original time dependent initial value problem is changed to an interpolation problem for the initial values of the generalized expansion coefficients. A physically meaningful and efficient extension velocity method is presented to avoid possible problems without reinitialization in the level set methods. The proposed method is implemented in the framework of minimum compliance design that has been extensively studied in topology optimization and its efficiency and accuracy over the conventional level set methods are highlighted. Numerical examples show the success of the present RBF–level set method in the accuracy, convergence speed and insensitivity to initial designs in topology optimization of two‐dimensional (2D) structures. It is suggested that the introduction of the radial basis functions to the level set methods can be promising in structural topology optimization. Copyright © 2005 John Wiley & Sons, Ltd.     

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.     

Multi-material plastic part design via the level set shape and topology optimization method

This work presents a new multi-material level set topology optimization method which is developed especially for designing plastic parts. Instead of representing the structure using multiple level set functions, this new method employs only one level set function to describe the material/void interface. The injection moulding filling simulation is used to determine the material/material interfaces. Because plastic parts are targeted, domain-specific knowledge is carefully investigated to improve the optimization algorithm. Both homogeneous and heterogeneous fibre-reinforced plastics are considered as potential material phases. For the latter, one extra design freedom, fibre orientation distribution, is introduced. Instead of generating incremental interior voids, which complicates the mould design and part ejection, shape-fixed interior voids could be predefined inside the design domain for functional or assembly purposes. This is represented by an additional level set function. A few numerical examples are studied to demonstrate the effectiveness of the proposed method.     

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.     

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.     

Topology optimization using bi-directional evolutionary structural optimization based on the element-free Galerkin method

In this article, the bi-directional evolutionary structural optimization (BESO) method based on the element-free Galerkin (EFG) method is presented for topology optimization of continuum structures. The mathematical formulation of the topology optimization is developed considering the nodal strain energy as the design variable and the minimization of compliance as the objective function. The EFG method is used to derive the shape functions using the moving least squares approximation. The essential boundary conditions are enforced by the method of Lagrange multipliers. Several topology optimization problems are presented to show the effectiveness of the proposed method. Many issues related to topology optimization of continuum structures, such as chequerboard patterns and mesh dependency, are studied in the examples.     

A level set approach for topology optimization with local stress constraints

The purpose of this work is to present a level set‐based approach for the structural topology optimization problem of mass minimization submitted to local stress constraints. The main contributions are threefold. First, the inclusion of local stress constraints by means of an augmented Lagrangian approach within the level set context. Second, the proposition of a constraint procedure that accounts for a continuous activation/deactivation of a finite number of local stress constraints during the optimization sequence. Finally, the proposition of a logarithmic scaling of the level set normal velocity as an additional regularization technique in order to improve the minimization sequence. A set of benchmark tests in two dimensions achieving successful numerical results assesses the good behavior of the proposed method. In these examples, it is verified that the algorithm is able to identify stress concentrations and drive the design to a feasible local minimum. Copyright © 2014 John Wiley & Sons, Ltd.     

Topology optimization of hinge-free compliant mechanisms using level set methods

A new level set-based multi-objective optimization method is proposed for topological design of hinge-free compliant mechanisms. Firstly, the flexibility requirement of compliant mechanisms is formulated by using the mutual energy. Two types of mean compliance are developed to meet the stiffness requirement. Secondly, several objective functions are developed for designing hinge-free compliant mechanisms based on the weighting method in which a new scheme for determining weighting factors is used. Thirdly, several numerical examples are performed to demonstrate the validity of the proposed method. It is shown that the resulting compliant mechanism configurations contain only strip-like members which are suitable for generating distributed compliance and decreasing stress concentration.     

Bi-directional evolutionary structural optimization for design-dependent fluid pressure loading problems

This article presents an evolutionary topology optimization method for compliance minimization of structures under design-dependent pressure loads. In traditional density based topology optimization methods, intermediate values of densities for the solid elements arise along the iterations. Extra boundary parametrization schemes are demanded when these methods are applied to pressure loading problems. An alternative methodology is suggested in this article for handling this type of load. With an extended bi-directional evolutionary structural optimization method associated with a partially coupled fluid–structure formulation, pressure loads are modelled with hydrostatic fluid finite elements. Due to the discrete nature of the method, the problem is solved without any need of pressure load surfaces parametrization. Furthermore, the introduction of a separate fluid domain allows the algorithm to model non-constant pressure fields with Laplace's equation. Three benchmark examples are explored in order to show the achievements of the proposed method.     

Bi-directional evolutionary structural optimization for strut-and-tie modelling of three-dimensional structural concrete

This article presents a method for the automatic generation of optimal strut-and-tie models in reinforced concrete structures using a bi-directional evolutionary structural optimization method. The methodology presented is developed for compliance minimization relying on the Abaqus finite element software package. The proposed approach deals with the generation of truss-like designs in a three-dimensional environment, addressing the design of corbels and joints as well as bridge piers and pile caps. Several three-dimensional examples are provided to show the capabilities of the proposed framework in finding optimal strut-and-tie models in reinforced concrete structures and verifying its efficiency to cope with torsional actions. Several issues relating to the use of the topology optimization for strut-and-tie modelling of structural concrete, such as chequerboard patterns, mesh-dependency and multiple load cases, are studied. In the last example, a design procedure for detailing and dimensioning of the strut-and-tie models is given according to the American Concrete Institute (ACI) 318-08 provisions.     

Parametric shape and topology optimization: A new level set approach based on cardinal basis functions

The parametric level set approach is an extension of the conventional level set methods for topology optimization. By parameterizing the level set function, level set methods can be directly coupled with mathematical programming to achieve better numerical robustness and computational efficiency. Moreover, the parametric level set scheme can not only inherit the primary advantages of the conventional level set methods, such as clear boundary representation and the flexibility in handling topological changes, but also alleviate some undesired features from the conventional level set methods, such as the need for reinitialization. However, in the existing radial basis function–based parametric level set method, it is difficult to identify the range of the design variables. Besides, the parametric level set evolution often struggles with large fluctuations during the optimization process. Those issues cause difficulties both in numerical stability and in material property mapping. In this paper, a cardinal basis function is constructed based on the radial basis function partition of unity collocation method to parameterize the level set function. The benefit of using cardinal basis function is that the range of the design variables can now be clearly specified as the value of the level set function. A distance regularization energy functional is also introduced, aiming to maintain the desired signed distance property during the level set evolution. With this desired feature, the level set evolution is stabilized against large fluctuations. In addition, the material properties mapped from the level set function to the finite element model can be more accurate.     

A level set‐based topology optimization method targeting metallic waveguide design problems

In this paper, we propose a level set‐based topology optimization method targeting metallic waveguide design problems, where the skin effect must be taken into account since the metallic waveguides are generally used in the high‐frequency range where this effect critically affects performance. One of the most reasonable approaches to represent the skin effect is to impose an electric field constraint condition on the surface of the metal. To implement this approach, we develop a boundary‐tracking scheme for the arbitrary Lagrangian Eulerian (ALE) mesh pertaining to the zero iso‐contour of the level set function that is given in an Eulerian mesh, and impose Dirichlet boundary conditions at the nodes on the zero iso‐contour in the ALE mesh to compute the electric field. Since the ALE mesh accurately tracks the zero iso‐contour at every optimization iteration, the electric field is always appropriately computed during optimization. For the sensitivity analysis, we compute the nodal coordinate sensitivities in the ALE mesh and smooth them by solving a Helmholtz‐type partial differential equation. The obtained smoothed sensitivities are used to compute the normal velocity in the level set equation that is solved using the Eulerian mesh, and the level set function is updated based on the computed normal velocity. Finally, the utility of the proposed method is discussed through several numerical examples. Copyright © 2011 John Wiley & Sons, Ltd.     

Optimal topology design of continuum structures with stress concentration alleviation via level set method

Although the phenomenon of stress concentration is of paramount importance to engineers when they are designing load‐carrying structures, stiffness is often used as the solely concerned objective or constraint functional in the studies of optimal topology design of continuum structures. Sometimes this will lead to optimal designs with severe stress concentrations that may be highly responsible for the fracture, creep, and fatigue of structures. The aim of the present work is to develop some effective numerical techniques for designing stiff structures with less stress concentrations. This is achieved by introducing some specific stress measures, which are sensitive to the existence of high local stresses, in the problem formulation and resolving the corresponding optimization problem numerically in a level set framework. Our study indicates that with use of the proposed numerical schemes, some intrinsic difficulties in stress‐related topology optimization of continuum structures can be overcome in a natural way. Copyright © 2012 John Wiley & Sons, Ltd.