Weakly and fully coupled methods for structural optimization of flexible mechanisms

The paper concerns a detailed comparison between two optimization methods that are used to perform the structural optimization of flexible components within a multibody system (MBS) simulation. The dynamic analysis of flexible MBS is based on a nonlinear finite element formulation. The first method is a weakly coupled method, which reformulates the dynamic response optimization problem in a two-level approach. First, a rigid or flexible MBS simulation is performed, and second, each component is optimized independently using a quasi-static approach in which a series of equivalent static load (ESL) cases obtained from the MBS simulation are applied to the respective components. The second method, the fully coupled method, performs the dynamic response optimization using the time response obtained directly from the flexible MBS simulation. Here, an original procedure is proposed to evaluate the ESL from a nonlinear finite element simulation, contrasting with the floating reference frame formulation exploited in the standard ESL method. Several numerical examples are provided to support our position. It is shown that the fully coupled method is more general and accommodates all types of constraints at the price of a more complex optimization process.