Topology optimization for microstructural design under stress constraints

This work aims at introducing stress responses within a topology optimization framework applied to the design of periodic microstructures. The emergence of novel additive manufacturing techniques fosters research towards new approaches to tailor materials properties. This paper derives a formulation to prevent the occurrence of high stress concentrations, often present in optimized microstructures. Applying macroscopic test strain fields to the material, microstructural layouts, reducing the stress level while exhibiting the best overall stiffness properties, are sought for. Equivalent stiffness properties of the designed material are predicted by numerical homogenization and considering a metallic base material for the microstructure, it is assumed that the classical Von Mises stress criterion remains valid to predict the material elastic allowable stress at the microscale. Stress constraints with arbitrary bounds are considered, assuming that a sizing optimization step could be applied to match the actual stress limits under realistic service loads. Density–based topology optimization, relying on the SIMP model, is used and the qp–approach is exploited to overcome the singularity phenomenon arising from the introduction of stress constraints with vanishing material. Optimization problems are solved using mathematical programming schemes, in particular MMA, so that a sensitivity analysis of stress responses at the microstructural level is required and performed considering the adjoint approach. Finally, the developed method is first validated with classical academic benchmarks and then illustrated with an original application: tailoring metamaterials for a museum anti–seismic stand.