A new optimality criteria method for shape optimization of natural frequency problems

A new shape optimization method for natural frequency problems is presented. The approach is based on an optimality criterion for general continuum solids, which is derived in this paper for the maximization of the first natural frequency with a volume constraint. An efficient redesign rule for frequency problems is developed to achieve the required shape modifications. The optimality criterion is extended to volume minimization problems with multiple frequency constraints. The nonparametric geometry representation creates a complete design space for the optimization problem, which includes all possible solutions for the finite element discretization. The combination with the optimality criteria approach results in a robust and fast convergence, which is independent of the number of design variables. Sensitivity information of objective function and constraints are not required, which allows to solve the structural analysis task using fast and reliable industry standard finite element solvers like ABAQUS, ANSYS, I-DEAS, MARC, NASTRAN, or PERMAS. The new approach is currently being implemented in the optimization system TOSCA.     

Eulerian shape design sensitivity analysis and optimization with a fixed grid

Conventional shape optimization based on the finite element method uses Lagrangian representation in which the finite element mesh moves according to shape change, while modern topology optimization uses Eulerian representation. In this paper, an approach to shape optimization using Eulerian representation such that the mesh distortion problem in the conventional approach can be resolved is proposed. A continuum geometric model is defined on the fixed grid of finite elements. An active set of finite elements that defines the discrete domain is determined using a procedure similar to topology optimization, in which each element has a unique shape density. The shape design parameter that is defined on the geometric model is transformed into the corresponding shape density variation of the boundary elements. Using this transformation, it has been shown that the shape design problem can be treated as a parameter design problem, which is a much easier method than the former. A detailed derivation of how the shape design velocity field can be converted into the shape density variation is presented along with sensitivity calculation. Very efficient sensitivity coefficients are calculated by integrating only those elements that belong to the structural boundary. The accuracy of the sensitivity information is compared with that derived by the finite difference method with excellent agreement. Two design optimization problems are presented to show the feasibility of the proposed design approach.     

Shape design sensitivity analysis of nonlinear structural systems

A unified approach is presented for shape design sensitivity analysis of nonlinear structural systems that include trusses and beams. Both geometric and material nonlinearities are considered. Design variables that specify the shape of components of built-up structures are treated, using the continuum equilibrium equations and the material derivative concept. To best utilize the basic character of the finite element method, shape design sensitivity information is expressed as domain integrals. For numerical evaluation of shape design sensitivity expressions, two alternative methods are presented: the adjoint variable and direct differentiation methods. Advantages and disadvantages of each method are discussed. Using the domain formulation of shape design sensitivity analysis, and the adjoint variable and direct differentiation methods, design sensitivity expressions are derived in the continuous setting in terms of shape design variations. A numerical method to implement the shape design sensitivity analysis, using established finite element codes, is discussed. Unlike conventional methods, the current approach does not require differentiation of finite element stiffness and mass matrices.     

Damping optimization of viscoelastic laminated sandwich composite structures

Recent developments on the optimization of passive damping for vibration reduction in sandwich structures are presented in this paper, showing the importance of appropriate finite element models associated with gradient based optimizers for computationally efficient damping maximization programs. A new finite element model for anisotropic laminated plate structures with viscoelastic core and laminated anisotropic face layers has been formulated, using a mixed layerwise approach. The complex modulus approach is used for the viscoelastic material behavior, and the dynamic problem is solved in the frequency domain. Constrained optimization is conducted for the maximization of modal loss factors, using gradient based optimization associated with the developed model, and single and multiobjective optimization based on genetic algorithms using an alternative ABAQUS finite element model. The model has been applied successfully and comparative optimal design applications in sandwich structures are presented and discussed.     

Second-order shape design sensitivity using P-version finite element analysis

Thep-version finite element analysis (FEA) approach is attractive for design sensitivity analysis (DSA) and optimization due to its high accuracy of analysis results, even with coarse mesh; insensitivity to finite element mesh distortion and aspect ratio; and tolerance for large shape design changes during design iterations. A continuum second-order shape DSA formulation is derived and implemented usingp-version FEA. The second-order shape design sensitivity can be used for reliability based analysis and design optimization by incorporating it with the second-order reliability analysis method (SORM). Both the second-order shape DSA formulations with respect to the single and mixed shape design parameters are derived for elastic solids using the material derivative concept. Both the direct differentiation and hybrid methods are presented in this paper. A shape DSA is implemented by using an establishedp-version FEA code, STRESS CHECK. Two numerical examples, a connecting rod and bracket, are presented to demonstrate the feasibility and accuracy of the proposed seond-order shape DSA approach.     

Optimization of geometrically nonlinear thin-walled structures using the multipoint approximation method

The present study concentrates on the optimization of geometrically nonlinear shell structures using the multipoint approximation approach. The latter is an iterative technique, which uses a succession of approximations for the implicit objective and constraint functions. These approximations are formulated by means of multiple regression analysis. In each iteration the technique enables the use of results gained at several previous design points. The approximate functions obtained are considered to be valid within a current subregion of the space of design variables defined by move limits. A geometrically nonlinear curved triangular thin shell element with the corner node displacements and the mid-side rotations as degrees of freedom is used for the FE analysis. The influence of initial shape imperfections on the optimum designs is investigated. Imperfections are considered as a shape distortion proportional to the lowest buckling modes of the perfect structure. Displacement, stress, and stability constraints are taken into account. To prevent finite element solutions from becoming unstable during the optimization process, a simple strategy for avoiding passage of stability points is applied. Some numerical examples are solved to show the practical use and efficiency of the technique presented.     

Integration of topology and shape optimization for design of structural components

This paper presents an integrated approach that supports the topology optimization and CAD-based shape optimization. The main contribution of the paper is using the geometric reconstruction technique that is mathematically sound and error bounded for creating solid models of the topologically optimized structures with smooth geometric boundary. This geometric reconstruction method extends the integration to 3-D applications. In addition, commercial Computer-Aided Design (CAD), finite element analysis (FEA), optimization, and application software tools are incorporated to support the integrated optimization process. The integration is carried out by first converting the geometry of the topologically optimized structure into smooth and parametric B-spline curves and surfaces. The B-spline curves and surfaces are then imported into a parametric CAD environment to build solid models of the structure. The control point movements of the B-spline curves or surfaces are defined as design variables for shape optimization, in which CAD-based design velocity field computations, design sensitivity analysis (DSA), and nonlinear programming are performed. Both 2-D plane stress and 3-D solid examples are presented to demonstrate the proposed approach. Received January 27, 2000 Communicated by J. Sobieski     

Regularization of shape optimization problems using FE-based parametrization

This paper introduces a general fully stabilized mesh based shape optimization strategy, which allows for shape optimization of mechanical problems on FE-based parametrization. The well-known mesh dependent results are avoided by application of filter methods and mesh regularization strategies. Filter methods are successfully applied to SIMP (Solid Isotropic Material with Penalization) based topology optimization for many years. The filter method presented here uses a specific formulation that is based on convolution integrals. It is shown that the filter methods ensure mesh independency of the optimal designs. Furthermore they provide an easy and robust tool to explore the whole design space with respect to optimal designs with similar mechanical properties. A successful application of optimization strategies with FE-based parametrization requires the combination of filter methods with mesh regularization strategies. The latter ones ensure reliable results of the finite element solutions that are crucial for the sensitivity analysis. This presentation introduces a new mesh regularization strategy that is based on the Updated Reference Strategy (URS). It is shown that the methods formulated on this mechanical basis result in fast and robust mesh regularization methods. The resulting grids show a minimum mesh distortion even for large movements of the mesh boundary. The performance of the proposed regularization methods is demonstrated by several illustrative examples.     

A general purpose real-world structural design optimization computing platform

Structural optimization has matured from a narrow academic discipline, where researchers focused on optimum design of small idealized structural components and systems, to become the basis in modern design of complex structural systems. Some software applications in recent years have made these tools accessible to professional engineers, decision-makers and students outside the structural optimization research community. These software applications, mainly focused on aerospace, aeronautical, mechanical and naval structural systems, have incorporated the optimization component as an additional feature of the finite element software package. On the other hand though there is not a holistic optimization approach in terms of final design stage for real-world civil engineering structures such as buildings, bridges or more complex civil engineering structures. The optimization computing platform presented in this study is a generic real-world optimum design computing platform for civil structural systems and it is implemented within an innovative computing framework, founded on the current state of the art in topics like metaheuristic optimization, structural analysis and parallel computing. For demonstration purposes the application of the optimization computing platform in five real-world design projects is presented.     

A three-dimensional shape optimization system—shop3D

A modular approach for shape optimization of three-dimensional solid structures is described. A major consideration in the development of this capability is the desire to use a commercially available finite element program, such as NASTRAN, for analysis. Since NASTRAN cannot be called as a subroutine, a system architecture was developed of independently executable modules in which sequential execution is controlled by job control language. Also, shape sensitivities are not commonly available in commercial programs. A hybrid approach which is based on the material derivative concept is developed to obtain shape sensitivities by post processing finite element results stored on files. A quick generation of a good optimization model combined with an efficient optimization system will result in a drastic design time saving. In this paper, different modeling approaches for shape optimization are discussed. Emphasis will be placed upon a special modeling technique which overlays the design model onto an already existing finite element model. Several automotive related examples are used to evaluate the program's effectiveness.     

Shape optimal design of an engine exhaust manifold

An engine exhaust manifold made of cast iron cracks during thermal shock testing. The test process is simulated by finite element analysis. The manifold is formulated as a linear heat transfer and thermoelasticity problem in a variational form. Analytical expressions for shape design sensitivities of general three-dimensional problems are presented, using the material derivative approach. A hybrid approach is described and used during the optimization process. This approach takes advantage of the direct and the adjoint variable methods and is the most efficient in calculating the sensitivity of the structural responses. After the finite element model is verified by comparing the results with those from testing, the engine exhaust manifold is optimized with respect to its geometry.     

Weight optimization for flexural reinforced concrete beams with static nonlinear response

The weight optimization of reinforced concrete (RC) beams with material nonlinear response is formulated as a general nonlinear optimization problem. Incremental finite element procedures are used to integrate the structural response analysis and design sensitivity analysis in a consistent manner. In the finite element discretization, the concrete is modelled by plane stress elements and steel reinforcement is modelled by discrete truss elements. The cross-sectional areas of the steel and the thickness of the concrete are chosen as design variables, and design constraints can include the displacement, stress and sizing constraints. The objective function is the weight of the RC beams. The optimal design is performed by using the sequential linear programming algorithm for the changing process of design variables, and the gradient projection method for the calculations of the search direction. Three example problems are considered. The first two are demonstrated to show the stability and accuracy of the approaches by comparing previous results for truss and plane stress elements, separately. The last one is an example of an RC beam. Comparative cost objective functions are presented to prove the validity of the approach.     

Nonlinear topology optimization of layered shell structures

Topology stiffness (compliance) design of linear and geometrically nonlinear shell structures is solved using the SIMP approach together with a filtering scheme. A general anisotropic multi-layer shell model is employed to allow the formation of through-the-thickness holes or stiffening zones. The finite element analysis is performed using nine-node Mindlin-type shell elements based on the degenerated shell approach, which are capable of modeling both single and multi-layered structures exhibiting anisotropic or isotropic behavior. The optimization problem is solved using analytical compliance and constraint sensitivities together with the Method of Moving Asymptotes (MMA). Geometrically nonlinear problems are solved using iterative Newton–Raphson methods and an adjoint variable approach is used for the sensitivity analysis. Several benchmark tests are presented in order to illustrate the difference in optimal topologies between linear and geometrically nonlinear shell structures.     

A systematic approach for generating velocity fields in shape optimization

Design velocity fields affect every stage of the shape optimization process. The progress of the optimization process, distortion of the finite element mesh, and final shape are sensitive to the quality of velocity fields. It is important to identify and generate effective velocity fields at the beginning of the process. This paper provides several criteria to determine the effectiveness of velocity fields. A systematic approach for generating these velocity fields using deformation fields is developed. The use of interactive procedures is shown to be indispensable for ensuring the effectiveness and quality of design velocity fields. General strategies and guidelines for generating velocity fields are given. Concepts of weight-reducing, stress-reducing, form-preserving, and smooth basis shapes are presented. Normalization of velocity fields is discussed. A method for controlling mesh distortion during the shape optimization process is given based on an explicit limit on the design change to prevent the Jacobian from vanishing. Two- and three-dimensional design problems are solved.     

Optimum shape design of rotating disks

This paper deals with optimum shape design of the rotating disks by nonlinear programming method. The shape of the cross section is defined by 5th degree polynomial which is completely determined by the boundary conditions and four design variables. The stress analysis of the disk is carried out by finite element method using isoparametric elements. The optimization technique used is with improved movelimit method of sequential linear programming. Progress of optimization is investigated with three different objective functions. After preliminary studies a weighted objective function is selected for detailed investigation. Optimum shapes are obtained for different speeds and for different fit pressures from hub. The results are presented in non-dimensionalised form.     

Shape optimization of continua using NURBS as basis functions

The present paper introduces a numerical solution to shape optimization problems of domains in which boundary value problems of partial differential equations are defined. In the present paper, the finite element method using NURBS as basis functions in the Galerkin method is applied to solve the boundary value problems and to solve a reshaping problem generated by the H1 gradient method for shape optimization, which has been developed as a general solution to shape optimization problems. Numerical examples of linear elastic continua illustrate that this solution works as well as using the conventional finite element method.     

Real-time optimization and nonlinear model predictive control of processes governed by differential-algebraic equations

Optimization problems in chemical engineering often involve complex systems of nonlinear DAE as the model equations. The direct multiple shooting method has been known for a while as a fast off-line method for optimization problems in ODE and later in DAE. Some factors crucial for its fast performance are briefly reviewed. The direct multiple shooting approach has been successfully adapted to the specific requirements of real-time optimization. Special strategies have been developed to effectively minimize the on-line computational effort, in which the progress of the optimization iterations is nested with the progress of the process. They use precalculated information as far as possible (e.g. Hessians, gradients and QP presolves for iterated reference trajectories) to minimize response time in case of perturbations. In typical real-time problems they have proven much faster than fast off-line strategies. Compared with an optimal feedback control computable upper bounds for the loss of optimality can be established that are small in practice. Numerical results for the Nonlinear Model Predictive Control (NMPC) of a high-purity distillation column subject to parameter disturbances are presented.     

Numerical method for shape optimization using T-spline based isogeometric method

Numerical methods for shape design sensitivity analysis and optimization have been developed for several decades. However, the finite-element-based shape design sensitivity analysis and optimization have experienced some bottleneck problems such as design parameterization and design remodeling during optimization. In this paper, as a remedy for these problems, an isogeometric-based shape design sensitivity analysis and optimization methods are developed incorporating with T-spline basis. In the shape design sensitivity analysis and optimization procedure using a standard finite element approach, the design boundary should be parameterized for the smooth variation of the boundary using a separate geometric modeler, such as a CAD system. Otherwise, the optimal design usually tends to fall into an undesirable irregular shape. In an isogeometric approach, the NURBS basis function that is used in representing the geometric model in the CAD system is directly used in the response analysis, and the design boundary is expressed by the same NURBS function as used in the analysis. Moreover, the smoothness of the NURBS can allow the large perturbation of the design boundary without a severe mesh distortion. Thus, the isogeometric shape design sensitivity analysis is free from remeshing during the optimization process. In addition, the use of T-spline basis instead of NURBS can reduce the number of degrees of freedom, so that the optimal solution can be obtained more efficiently while yielding the same optimum design shape.