Topology optimization of continuum structures under hybrid additive-subtractive manufacturing constraints

Structural and Multidisciplinary Optimization - Additive manufacturing (AM) makes it possible to fabricate complicated parts that are otherwise difficult to manufacture by subtractive machining....     

Topology optimization under topologically dependent material uncertainties

Structural and Multidisciplinary Optimization - A methodology allowing for the algorithmic integration of topologically dependent random fields of material parameters in topology optimization...     

Topology optimization of continuum structures with material failure constraints

This work presents an efficient strategy for dealing with topology optimization associated with the problem of mass minimization under material failure constraints. Although this problem characterizes one of the oldest mechanical requirements in structural design, only a few works dealing with this subject are found in the literature. Several reasons explain this situation, among them the numerical difficulties introduced by the usually large number of stress constraints. The original formulation of the topological problem (existence/non-existence of material) is partially relaxed by following the SIMP (Solid Isotropic Microstructure with Penalization) approach and using a continuous density field as the design variable. The finite element approximation is used to solve the equilibrium problem, as well as to control through nodal parameters. The formulation accepts any failure criterion written in terms of stress and/or strain invariants. The whole minimization problem is solved by combining an augmented Lagrangian technique for the stress constraints and a trust-region box-type algorithm for dealing with side constraints (0<_min1) . Numerical results show the efficiency of the proposed approach in terms of computational costs as well as satisfaction of material failure constraints. It is also possible to see that the final designs define quite different shapes from the ones obtained in classical compliance problems.     

Topology optimization of freely vibrating continuum structures based on nonsmooth optimization

The non-differentiability of repeated eigenvalues is one of the key difficulties to obtain the optimal solution in the topology optimization of freely vibrating continuum structures. In this paper, the bundle method, which is a very promising one in the nonsmooth optimization algorithm family, is proposed and implemented to solve the problem of eigenfrequency optimization of continuum. The bundle method is well-known in the mathematical programming community, but has never been used to solve the problems of topology optimization of continuum structures with respect to simple or multiple eigenfrequencies. The advantage of this method is that the specified information of iteration history may be collected and utilized in a very efficient manner to ensure that the next stability center is closer to the optimal solution, so as to avoid the numerical oscillation in the iteration history. Moreover, in the present method, both the simple and multiple eigenfrequencies can be managed within a unified computational scheme. Several numerical examples are tested to validate the proposed method. Comparisons with nonlinear semidefinite programming method and 0–1 formulation based heuristic method show the advantages of the proposed method. It is showed that, the method can deal with the nonsmoothness of the repeated eigenvalues in topology optimization in a very effective and efficient manner without evaluating the multiplicity of the eigenvalues.     

Topology optimization of continuum structures subjected to pressure loading

This paper presents a generalization of topology optimization of linearly elastic continuum structures to problems involving loadings that depend on the design. Minimum compliance is chosen as the design objective, assuming the boundary conditions and the total volume within the admissible design domain to be given. The topology optimization is based on the usage of a SIMP material model. The type of loading considered in this paper occurs if free structural surface domains are subjected to static pressure, in which case both the direction and location of the loading change with the structural design. The presentation of the material is given in a 2D context, but an extension to 3D is straightforward. The robustness of the optimization method is illustrated by some numerical examples in the end of the paper. Received August 3, 1999     

Topology optimization of truss-like continuum structures for natural frequencies

A method to maximize the natural frequencies of vibration of truss-like continua with the constraint of material volume is presented. Truss-like is a kind of particular anisotropic continuum, in which there are finite numbers of members with infinitesimal spaces. Structures are analyzed by finite element method. The densities and orientations of members at nodes are taken as design variables. The densities and orientations of members in elements are interpolated by these values at nodes; therefore they vary continuously in design domain. For no intermediate densities being suppressed, there is no numerical instability, such as checkerboard patterns and one-node connected hinges. The natural frequency and its sensitivities of truss-like continuum are derived. Optimization is achieved by the techniques of moving asymptotes and steepest descent. Several numerical examples are provided to demonstrate this optimization method.     

Topology optimization of continuum structures with local and global stress constraints

Topology structural optimization problems have been usually stated in terms of a maximum stiffness (minimum compliance) approach. The objective of this type of approach is to distribute a given amount of material in a certain domain, so that the stiffness of the resulting structure is maximized (that is, the compliance, or energy of deformation, is minimized) for a given load case. Thus, the material mass is restricted to a predefined percentage of the maximum possible mass, while no stress or displacement constraints are taken into account. This paper presents a different strategy to deal with topology optimization: a minimum weight with stress constraints Finite Element formulation for the topology optimization of continuum structures. We propose two different approaches in order to take into account stress constraints in the optimization formulation. The local approach of the stress constraints imposes stress constraints at predefined points of the domain (i.e. at the central point of each element). On the contrary, the global approach only imposes one global constraint that gathers the effect of all the local constraints by means of a certain so-called aggregation function. Finally, some application examples are solved with both formulations in order to compare the obtained solutions.     

Topology and shape optimization of continuum structures using GA and BEM

In a previous study, the authors presented a shape optimization scheme for continuum structures by a genetic algorithm and a boundary element method. In this paper, the study is extended to topology and shape optimization problems of the continuum structures.Boundary profiles are expressed by spline functions. The chromosomes for the profiles are defined by a gene related to the topology (the number of internal boundaries) and genes related to the control points of the spline functions. The population is constructed by individuals with such chromosomes. The genetic opertors such as selection, crossover and mutation are applied to the population for searching the profile satisfying the design objectives. In the case of the objects with internal boundaries, intersection of the boundaries very often occurs and thus, the computational cost may become high. Therefore, we also discuss a scheme for increasing the computational efficiency in this case. Finally, the present scheme is applied to the topology and shape optimization of a plate in order to confirm its validity.     

Topology optimization for crashworthiness of thin-walled structures under axial impact using hybrid cellular automata

Although topology optimization is well established in most engineering fields, it is still in its infancy concerning highly non-linear structural applications like vehicular crashworthiness. One of the approaches recently proposed and based on Hybrid Cellular Automata is modified here such that it can be applied for the first time to thin-walled structures. Classical methods based on voxel techniques, i.e., on solid three-dimensional volume elements, cannot derive structures made from thin metal sheets where the main energy absorption mode is related to plastic buckling, folding and failure. Because the main components of car structures are made from such thin-walled beams and panels, a special approach using SFE CONCEPT was developed, which is presented in this paper.     

Topology optimization of dynamic stress response reliability of continuum structures involving multi-phase materials

This paper proposes a methodology for maximizing dynamic stress response reliability of continuum structures involving multi-phase materials by using a bi-directional evolutionary structural optimization (BESO) method. The topology optimization model is built based on a material interpolation scheme with multiple materials. The objective function is to maximize the dynamic stress response reliability index subject to volume constraints on multi-phase materials. To solve the defined topology optimization problems, the sensitivity of the dynamic stress response reliability index with respect to the design variables is derived for iteratively updating the structural topology. Subsequently, an optimization procedure based on the BESO method is developed. Finally, a series of numerical examples of both 2D and 3D structures are presented to demonstrate the effectiveness of the proposed approach.

     

Topology optimization of continuum structures subjected to the variance constraint of reaction forces

In this paper, the attainment of uniform reaction forces at the specific fixed boundary is investigated for topology optimization of continuum structures. The variance of the reaction forces at the boundary between the elastic solid and its foundation is firstly introduced as the evaluation criterion of the uniformity of the reaction forces. Then, the standard formulation of optimal topology design is improved by introducing the variance constraint of the reaction forces. Sensitivity analysis of the latter is carried out based on the adjoint method. Numerical examples are dealt with to reveal the effect of the variance constraint in comparison with solutions of standard topology optimization.     

Topology optimization of phononic crystals with uncertainties

Topology optimization of phononic crystals (PnCs) is generally based on deterministic models without considering effects of inherent uncertainties existed in PnCs. However, uncertainties presented in PnCs may significantly affect band gap characteristics. To address this, an interval Chebyshev surrogate model-based heuristic algorithm is proposed for topology optimization of PnCs with uncertainties. Firstly, the interval model is introduced to handle the uncertainties, and then the interval Chebyshev surrogate model (ICSM), in which the improved fast plane wave expansion method (IFPWEM) is used to calculate the integral points to construct the ICSM, is introduced for band structure analysis with uncertainties efficiently. After that, the sample data, which is randomly generated by the Monte Carlo method (MCM), is applied to the ICSM for predicting the interval bounds of the band structures. Finally, topology optimization of PnCs is conducted to generate the widest band gaps with uncertainties included by utilizing the genetic algorithm (GA) and the ICSM. Numerical results show the effectiveness and efficiency of the proposed method which has promising prospects in a range of engineering applications.     

Topology optimization of free vibrating continuum structures based on the element free Galerkin method

In this paper, the topology optimization design of the free vibrating continuum structures is formulated based on the element free Galerkin (EFG) method. Considering the relative density of nodes as design variable, and the maximization of the fundamental eigenvalue as an objective function, the mathematical formulation of the topology optimization model is developed using the solid isotropic microstructures with penalization (SIMP) interpolation scheme. The topology optimization problem is solved by the optimality criteria method. Finally, the feasibility and efficiency of the proposed method are illustrated with several 2D examples that are widely used in the topology optimization design.     

Topology optimization with worst-case handling of material uncertainties

Structural and Multidisciplinary Optimization - In this article, a topology optimization method is developed, which is aware of material uncertainties. The uncertainties are handled in a worst-case...     

A non-probabilistic reliability-based topology optimization (NRBTO) method of continuum structures with convex uncertainties

This paper develops a non-probabilistic reliability-based topology optimization (NRBTO) framework for continuum structures under multi-dimensional convex uncertainties. Combined with the solid isotropic material with penalization (SIMP) model and the set-theoretical convex method, the uncertainty quantification (UQ) analysis is firstly conducted to obtain mathematical approximations and boundary laws of considered displacement responses. By normalization treatment of the limit-state function, a new quantified measure of the non-probabilistic reliability is then defined and further deduced by the principle of the hyper-volume ratio. For circumventing optimization difficulties arising from large-scale design variables, the adjoint vector scheme for sensitivity analysis of the reliability index with respect to design variables are discussed as well. Numerical applications eventually illustrate the applicability and the validity of the present problem statement as well as the proposed numerical techniques.     

Topology design of two-dimensional continuum structures using isolines

This paper presents the algorithm for the topological design of two-dimensional structures using isolines called isolines topology design (ITD). The topology and the shape of the design depend on an iterative algorithm, which continually adds and removes material depending on the shape and distribution of the contour isolines of the required structural behaviour. In this study the von Mises stress was investigated. Several classic examples are presented to show the effectiveness of the algorithm, which provides quality solutions with very detailed contour without the need to interpret the topology in order to obtain a final design.     

Topology design of three-dimensional continuum structures using isosurfaces

Isolines Topology Design (ITD) is an iterative algorithm for the topological design of two-dimensional continuum structures using isolines. This paper presents an extension to this algorithm for topology design of three-dimensional continuum structures. The topology and the shape of the design depend on an iterative algorithm, which continually adds and removes material depending on the shape and distribution of the contour isosurfaces for the required structural behaviour. In this study the von Mises stress was investigated. Several examples are presented to show the effectiveness of the algorithm, which produces final designs with very detailed surfaces without the need for interpretation. The results demonstrate how the ITD algorithm can produce realistic designs by using the design criteria contour isosurface.     

Topology optimization of continuum structures with different tensile and compressive properties in bridge layout design

In order to solve elasticity problems with dual extension/compression modulus this paper presents a technique that employ Heaviside function to describe the nonlinear relationship of stress and material modulus smoothing the constitutive discontinuity. An initial stress technique is utilized in the FEM based numerical analysis, which may lead to a higher computing efficiency since the stiffness matrix needs to be triangularized only once in the whole computing, moreover, avoid the inconvenience induced by choosing shear modulus in the conventional iterative algorithm. Furthermore, a multimaterial model is proposed to formulate the topology optimization problem for bridge layout designs. Two types of materials which are concrete and steels are distributed within the design domain to accommodate design need. In addition, sensitivity of the new material model is derived using the adjoint method. The effectiveness of the present design methodology and optimization scheme is then demonstrated through numerical examples.     

Topology optimization of nonlinear structures with damping under arbitrary dynamic loading

This study presents an extended unit load method in which the displacement of a chosen degree of freedom (DOF) in a nonlinear structure under arbitrary dynamic loading is expressed as an integration of mutual strain energy density over a continuum domain. This new integral formulation for the displacement of a chosen DOF is developed by using the virtual work principle and can be used for linear or nonlinear structural behaviours. The integral form of the displacement is then used to develop new formulations for structural topology optimization involving arbitrary dynamic loading using the moving iso-surface threshold (MIST) method. Presented are two specific topology optimization problems with two objective functions: (a) to minimize the peak of a chosen displacement; or (b) to minimize the average power spectral density (PSD) of the chosen displacement over a finite time interval. New MIST formulations and algorithms are developed for solving two damping topology optimization problems of a structure under arbitrary dynamic loading, with or without large displacements, and having cellular damping materials with multi-volume fractions. Several numerical examples are presented to demonstrate the validity and efficiency of the presented unit load method and the MIST formulations and algorithms.     

Topology optimization of softening structures under displacement constraints as an MPEC

This paper presents a mathematical programming based technique for the minimum weight (volume) topology optimization of truss-like structures such that strain softening material properties, that can lead to severe physical instability, can be accommodated. In addition, satisfaction of such serviceability criteria as limited displacements at some specific points is ensured. The problem is formulated in terms of truss member cross-sectional areas. This leads to a challenging nonconvex and nonsmooth optimization problem, known as a mathematical program with equilibrium constraints (MPEC). A two-step optimization algorithm is proposed to overcome the problems typically associated with nondefiniteness of some key matrices and at the same time nondifferentiability of the mathematical system. Each step involves updating the ground structure and solving the MPEC using a penalized nonlinear programming (NLP) approach. Some numerical examples are provided to illustrate application, robustness and efficiency of the proposed scheme. The safety and integrity of the designed topologically optimal structures are validated using appropriate stepwise holonomic elastoplastic analyses.