An element-by-element strategy for non-linear shape optimization

A strategy for the efficient solution of non-linear shape optimization problems is developed. This strategy employs an integrated element-by-element approach to the solution of the governing partial differential equations, and, more particularly, to the computation of the necessary gradients of the objective function and constraints using an adjoint formulation. This proves to be a very efficient strategy and also is relatively easy to implement, because the local effect of design changes can be exploited. The method is tested with an application involving the design of the shape of electromagnet poles in order to obtain a desired field in the interpolar region.     

Knowledge‐based algorithms in fixed‐grid GA shape optimization

Shape optimization through a genetic algorithm (GA) using discrete boundary steps and the fixed‐grid (FG) finite‐element analysis (FEA) concept was recently introduced by the authors. In this paper, algorithms based on knowledge specific to the FG method with the GA‐based shape optimization (FGGA) method are introduced that greatly increase its computational efficiency. These knowledge‐based algorithms exploit the information inherent in the system at any given instance in the evolution such as string structure and fitness gradient to self‐adapt the string length, population size and step magnitude. Other non‐adaptive algorithms such as string grouping and deterministic local searches are also introduced to reduce the number of FEA calls. These algorithms were applied to two examples and their effects quantified. The examples show that these algorithms are highly effective in reducing the number of FEA calls required hence significantly improving the computational efficiency of the FGGA shape optimization method. Copyright © 2003 John Wiley & Sons, Ltd.     

A multi-objective approach for multi-material topology and shape optimization

An automated multi-material approach that integrates multi-objective Topology Optimization (TO) and multi-objective shape optimization is presented. A new ant colony optimization algorithm is presented and applied to solving the TO problem, estimating a trade-off set of initial topologies or distributions of material. The solutions found usually present irregular boundaries, which are not desirable in applications. Thus, shape parameterization of the internal boundaries of the design region, and subsequent shape optimization, is performed to improve the quality of the estimated Pareto-optimal solutions. The selection of solutions for shape optimization is done by using the PROMETHEE II decision-making method. The parameterization process involves identifying the boundaries of different materials and describing these boundaries by non-uniform rational B-spline curves. The proposed approach is applied to the optimization of a C-core magnetic actuator, with two objectives: the maximization of the attractive force on the armature and the minimization of the volume of permanent magnet material.     

On structural shape optimization using an embedding domain discretization technique

This contribution presents a novel approach to structural shape optimization that relies on an embedding domain discretization technique. The evolving shape design is embedded within a uniform finite element background mesh which is then used for the solution of the physical state problem throughout the course of the optimization. We consider a boundary tracking procedure based on adaptive mesh refinement to separate between interior elements, exterior elements, and elements intersected by the physical domain boundary. A selective domain integration procedure is employed to account for the geometric mismatch between the uniform embedding domain discretization and the evolving structural component. Thereby, we avoid the need to provide a finite element mesh that conforms to the structural component for every design iteration, as it is the case for a standard Lagrangian approach to structural shape optimization. Still, we adopt an explicit shape parametrization that allows for a direct manipulation of boundary vertices for the design evolution process. In order to avoid irregular and impracticable design updates, we consider a geometric regularization technique to render feasible descent directions for the course of the optimization. Copyright © 2016 John Wiley & Sons, Ltd.     

A freeform shape optimization of complex structures represented by arbitrary polygonal or polyhedral meshes

In this paper we propose a new scheme for freeform shape optimization on arbitrary polygonal or polyhedral meshes. The approach consists of three main steps: (1) surface partitioning of polygonal meshes into different patches; (2) a new freeform perturbation scheme of using the Cox–de Boor basis function over arbitrary polygonal meshes, which supports multi‐resolution shape optimization and does not require CAD information; (3) freeform shape optimization of arbitrary polygonal or polyhedral meshes. Numerical experiments indicate the effectiveness of the proposed approach. Copyright © 2004 John Wiley & Sons, Ltd.     

A boundary‐perturbation finite element approach for shape optimization

A numerical method is proposed for the efficient solution of shape optimization problems, which combines the boundary perturbation technique and finite element analysis. The method is computationally efficient in that it requires a number of finite element analyses with a fixed geometry, as opposed to standard shape optimization which requires re‐analysis with varying geometry. The application of the method to general shape optimization is considered. In addition, a special optimization scheme is devised for a class of problems governed by linear partial differential equations. The performance of the method is illustrated via an example which involves acoustic wave scattering from an obstacle. Copyright © 2000 John Wiley & Sons, Ltd.     

Arterial cannula shape optimization by means of the rotational firefly algorithm

This article presents global optimization results of arterial cannula shapes by means of the newly modified firefly algorithm. The search for the optimal arterial cannula shape is necessary in order to minimize losses and prepare the flow that leaves the circulatory support system of a ventricle (i.e. blood pump) before it reaches the heart. A modification of the standard firefly algorithm, the so-called rotational firefly algorithm, is introduced. It is shown that the rotational firefly algorithm allows for better exploration of search spaces which results in faster convergence and better solutions in comparison with its standard version. This is particularly pronounced for smaller population sizes. Furthermore, it maintains greater diversity of populations for a longer time. A small population size and a low number of iterations are necessary to keep to a minimum the computational cost of the objective function of the problem, which comes from numerical solution of the nonlinear partial differential equations. Moreover, both versions of the firefly algorithm are compared to the state of the art, namely the differential evolution and covariance matrix adaptation evolution strategies.     

Sensitivity analysis and shape optimization in nonlinear solid mechanics

The objective of this paper is twofold. First, it presents a boundary element formulation for sensitivity analysis for solid mechanics problems involving both material and geometric nonlinearities. The second focus is on the use of such sensitivities to obtain optimal design for problems of this class. Numerical examples include sensitivity analysis for small (material nonlinearities only) and large deformation problems. These numerical results are in good agreement with direct integration results. Further, by using these sensitivities, a shape optimization problem has been solved for a plate with a cutout involving only material nonlinearities. The difference between the optimal shapes of solids, undergoing purely elastic or elasto-viscoplastic deformation is shown clearly in this example.     

Aerothermodynamic shape optimization of hypersonic blunt bodies

The aim of this study is to develop a reliable and efficient design tool that can be used in hypersonic flows. The flow analysis is based on the axisymmetric Euler/Navier–Stokes and finite-rate chemical reaction equations. The equations are coupled simultaneously and solved implicitly using Newton's method. The Jacobian matrix is evaluated analytically. A gradient-based numerical optimization is used. The adjoint method is utilized for sensitivity calculations. The objective of the design is to generate a hypersonic blunt geometry that produces the minimum drag with low aerodynamic heating. Bezier curves are used for geometry parameterization. The performances of the design optimization method are demonstrated for different hypersonic flow conditions.     

基于接触的捞雷具夹紧爪接触面形状优化

介绍了在捞雷具夹紧爪设计过程中引入的基于接触的有限元形状优化设计方法．传统的机械设计方法仅考虑了零件的几何尺寸，而对其形状的设计却考虑不够，导致设计结果不理想．文中将基于接触的有限元形状优化方法应用于传统的机械设计过程．对捞雷具夹紧爪建立基于有限元分析的优化设计模型，使夹紧爪既能满足打捞鱼雷的要求，又得到了优化的形状．结构的特性与受力状况均得到改善．     

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.     

Meshless approach to shape optimization of linear thermoelastic solids

This paper presents a formulation for shape optimization in thermoelasticity using a meshless method, namely the element‐free Galerkin method. Two examples are treated in detail and comparisons with previously published finite element analysis results demonstrate the excellent opportunities the EFG offers for solving these types of problems. Smoother stresses, no remeshing, and better accuracy than finite element solutions, permit answers to shape optimization problems in thermoelasticity that are practically unattainable with the classical FEM without remeshing. For the thermal fin example, the EFG finds finger shapes that are missed by the FEM analysis, and the objective value is greatly improved compared to the FEM solution. A study of the influence of the number of design parameters is performed and it is observed that the EFG can give better results with a smaller number of design parameters than is possible with traditional methods. Copyright © 2001 John Wiley & Sons, Ltd.     

Multi-objective aerodynamic shape optimization of small livestock trailers

This article presents a formal optimization study of the design of small livestock trailers, within which the majority of animals are transported to market in the UK. The benefits of employing a headboard fairing to reduce aerodynamic drag without compromising the ventilation of the animals’ microclimate are investigated using a multi-stage process involving computational fluid dynamics (CFD), optimal Latin hypercube (OLH) design of experiments (DoE) and moving least squares (MLS) metamodels. Fairings are parameterized in terms of three design variables and CFD solutions are obtained at 50 permutations of design variables. Both global and local search methods are employed to locate the global minimum from metamodels of the objective functions and a Pareto front is generated. The importance of carefully selecting an objective function is demonstrated and optimal fairing designs, offering drag reductions in excess of 5% without compromising animal ventilation, are presented.     

Shape optimization based design of arch-type dams under uncertainties

Comparing existing design methodologies for arch-type dams, model-based shape optimization can effectively reduce construction costs and leverage the properties of construction materials. To apply means of shape optimization, suitable variables need to be chosen to formulate the objective function, which is here the volume of the arch dam. A genetic algorithm is adopted as the optimization method, which allows a global search. The reliability index is considered as the main constraint. Its computation is realized by adaptive Kriging Monte Carlo simulation, which visibly increases the analysis efficiency compared with traditional Monte Carlo simulations. Constraints, such as the reliability index and further with respect to the geometry, are taken into consideration by a penalty formulation. By means of this approach, a reliability-based design can be found which ensures both the safety and serviceability of a newly designed arch-type dam.     

A three-dimensional shape optimization for transient acoustic scattering problems using the time-domain boundary element method

We develop a three-dimensional shape optimization (SO) framework for the wave equation with taking the unsteadiness into account. Resorting to the adjoint variable method, we derive the shape derivative (SD) with respect to a deformation (perturbation) of an arbitrary point on the target surface of acoustic scatterers. Successively, we represent the target surface with non-uniform rational B-spline patches and then discretize the SD in term of the associated control points (CPs), which are useful for manipulating a surface. To solve both the primary and adjoint problems, we apply the time-domain boundary element method (TDBEM) because it is the most appropriate when the analysis domain is the ambient air and thus infinitely large. The issues of the severe computational cost and instability of the TDBEM are resolved by exploiting the fast and stable TDBEM proposed by the present authors. Instead, since the TDBEM is mesh-based and employs the piecewise-constant element for space, we introduce some approximations in evaluating the discretized SD from the two solutions of TDBEM. By regarding the evaluation scheme as the computation of the gradient of the objective functional, given as the summation of the absolute value of the sound pressure over the predefined observation points, we can solve SO problems with a gradient-based non-linear optimization solver. To assess the developed SO system, we performed several numerical experiments from the perspective of verification and application with satisfactory results.     

Topology optimization of planar shape memory alloy thermal actuators using element connectivity parameterization

This paper presents the direct application of topology optimization to the design of shape memory alloy (SMA) thermal actuators. Because SMAs exhibit strongly nonlinear, temperature‐dependent material behavior, designing effective multidimensional SMA actuator structures is a challenging task. We pursue the use of topology optimization to address this problem. Conventional material scaling topology optimization approaches are hampered by the complexity of the SMA constitutive behavior combined with large actuator deflections. Therefore, for topology optimization we employ the element connectivity parameterization approach, which offers improved analysis convergence and robustness, as well as an unambiguous treatment of nonlinear materials. A path‐independent SMA constitutive model, aimed particularly at the NiTi R‐phase transformation, is employed, allowing efficient adjoint sensitivity analysis. The effectiveness of the proposed SMA topology optimization is demonstrated by numerical examples of constrained and unconstrained formulations of actuator stroke maximization, which provide insight into the characteristics of optimal SMA actuators. Copyright © 2011 John Wiley & Sons, Ltd.     

Implementation of regularized isogeometric boundary element methods for gradient‐based shape optimization in two‐dimensional linear elasticity

The present work addresses shape sensitivity analysis and optimization in two‐dimensional elasticity with a regularized isogeometric boundary element method (IGABEM). Non‐uniform rational B‐splines are used both for the geometry and the basis functions to discretize the regularized boundary integral equations. With the advantage of tight integration of design and analysis, the application of IGABEM in shape optimization reduces the mesh generation/regeneration burden greatly. The work is distinct from the previous literatures in IGABEM shape optimization mainly in two aspects: (1) the structural and sensitivity analysis takes advantage of the regularized form of the boundary integral equations, eliminating completely the need of evaluating strongly singular integrals and jump terms and their shape derivatives, which were the main implementation difficulty in IGABEM, and (2) although based on the same Computer Aided Design (CAD) model, the mesh for structural and shape sensitivity analysis is separated from the geometrical design mesh, thus achieving a balance between less design variables for efficiency and refined mesh for accuracy. This technique was initially used in isogeometric finite element method and was incorporated into the present IGABEM implementation. Copyright © 2016 John Wiley & Sons, Ltd.     

A parallel two‐level domain decomposition based one‐shot method for shape optimization problems

A two‐level domain decomposition method is introduced for general shape optimization problems constrained by the incompressible Navier–Stokes equations. The optimization problem is first discretized with a finite element method on an unstructured moving mesh that is implicitly defined without assuming that the computational domain is known and then solved by some one‐shot Lagrange–Newton–Krylov–Schwarz algorithms. In this approach, the shape of the domain, its corresponding finite element mesh, the flow fields and their corresponding Lagrange multipliers are all obtained computationally in a single solve of a nonlinear system of equations. Highly scalable parallel algorithms are absolutely necessary to solve such an expensive system. The one‐level domain decomposition method works reasonably well when the number of processors is not large. Aiming for machines with a large number of processors and robust nonlinear convergence, we introduce a two‐level inexact Newton method with a hybrid two‐level overlapping Schwarz preconditioner. As applications, we consider the shape optimization of a cannula problem and an artery bypass problem in 2D. Numerical experiments show that our algorithm performs well on a supercomputer with over 1000 processors for problems with millions of unknowns. Copyright © 2014 John Wiley & Sons, Ltd.     

Design synthesis and structural optimization of a lightweight,monobloc cast iron brake disc with fingered hub

This article focuses on generating a monobloc fingered hub (top-hat) disc design, aiming at reducing disc mass but maintaining rotor thermal capacity, while also improving heat dissipation characteristics. The analyses and tests demonstrated that such a design is possible to achieve, with mass reduction of just over 9%. The activities included research into cast iron modelling, which gave very important insights into the limits of mechanical performance under bending. Initial finite element analyses enabled considerable progress to be made towards establishing a baseline design, but only through shape optimization and topology optimization procedures was the full potential of the design accomplished. Shape optimization facilitated the reduction of maximum principal stress by 32%, considerably improving disc torsional strength with practically no increase in mass. The safety factor in torsion achieved a value of 3.57. Topology optimization provided further, although small, mass reduction (1.5%) while maintaining low stress levels.