An efficient multi-resolution topology optimization scheme for stiffness maximization and stress minimization

Topology optimization has been successful in generating optimal topologies of various structures arising in real-world applications. Since these applications can have complex and large domains, topology optimization suffers from a high computational cost because of the use of unstructured meshes for discretization of these domains and their finite element analysis (FEA). This article addresses this challenge by developing three graphics processing unit (GPU)-based element-by-element strategies targeting unstructured all-hexahedral mesh for the matrix-free precondition conjugate gradient (PCG) finite element solver. These strategies mainly perform sparse matrix multiplication (SpMV) arising with the FEA solver by allocating more compute threads of GPU per element. Moreover, the strategies are developed to use shared memory of GPU for efficient memory transactions. The proposed strategies are tested with solid isotropic material with penalization (SIMP) method on four examples of 3D structural topology optimization. Results demonstrate that the proposed strategies achieve speedup up to 8.2 × over the standard GPU-based SpMV strategies from the literature.

A several cycles of design-verification-modification are needed during traditional design, which is very time-consuming. Topology optimization is rapidly expanding in the recent years in the field of structural mechanics. Currently it is widely applied to structural design. The combination of topology optimization and sizing and/or shape optimization has been adopted for flight vehicle structural design, which results possible better designs. In the paper, continuum structural topology optimizations as well as size optimization are combined for a folding wing structural design. A structure optimization problem is established using Solid Isotropic Material with Penalization (SIMP) method, it consists of the thickness variable of the skin and the relative element density variables of the tip part of the folding wing. The design objective is to minimize the compliance of the whole structure, and the constraints are structural mass constraints and stress constraints. The problem was solved based on commercial software package HyperWorks™. The resulting design shows that a new tip structure which satisfies the requirements of stiffness and strength was reconstructed.

Topological optimization is an innovative method to realize the lightweight design. This paper proposes a hybrid topology optimization method that combines the SIMP (solid isotropic material with penalization) method and genetic algorithm (GA), called the SIMP-GA method. In the method, SIMP is used to update the chromosomes, which can accelerate convergence. The filtering scheme in the SIMP method can filter unconnected elements to ensure the connectivity of the structure. We studied the influence of varying the filtering radius on the optimized structure. Simultaneously, in the SIMP-GA method, each element is regarded as a gene, which controls the population number to a certain extent, reduces the amount of calculation, and improves the calculation efficiency. The calculation of some typical examples proves that the SIMP-GA method can obtain a better solution than the gradient-based method. Compared with the conventional genetic algorithm and GA-BESO (Bi-directional Evolutionary Structural Optimization) method, the calculation efficiency of the proposed method is higher and similar results are obtained. The innovative topology optimization method could be an effective way for structural lightweight design.

XFEM\\GFEM based approach for topology optimization of extruded beams with enhanced buckling resistance

The SIMP (solid isotropic material with penalization) approach is perhaps the most popular density variable relaxation method in topology optimization. This method has been very successful in many applications, but the optimization solution convergence can be improved when new variables, not the direct density variables, are used as the design variables. In this work, we newly propose S-shape functions mapping the original density variables nonlinearly to new design variables. The main role of S-shape function is to push intermediate densities to either lower or upper bounds. In particular, this method works well with nonlinear mathematical programming methods. A method of feasible directions is chosen as a nonlinear mathematical programming method in order to show the effects of the S-shape scaling function on the solution convergence.

A topology optimization approach based on the boundary element method (BEM) and the optimality criteria (OC) method is proposed for the optimal design of sound absorbing material distribution within sound barrier structures. The acoustical effect of the absorbing material is simplified as the acoustical impedance boundary condition. Based on the solid isotropic material with penalization (SIMP) method, a topology optimization model is established by selecting the densities of absorbing material elements as design variables, volumes of absorbing material as constraints, and the minimization of sound pressure at reference surface as design objective. A smoothed Heaviside-like function is proposed to help the SIMP method to obtain a clear 0---1 distribution. The BEM is applied for acoustic analysis and the sensitivities with respect to design variables are obtained by the direct differentiation method. The Burton---Miller formulation is used to overcome the fictitious eigen-frequency problem for exterior boundary-value problems. A relaxed form of OC is used for solving the optimization problem to find the optimal absorbing material distribution. Numerical tests are provided to illustrate the application of the optimization procedure for 2D sound barriers. Results show that the optimal distribution of the sound absorbing material is strongly frequency dependent, and performing an optimization in a frequency band is generally needed.

Graded porous structures combine robustness of porous structures and high stiffness of bulk designs. This study aims to design optimized graded porous bone-like structures through a novel multi-material topology optimization approach, which generalizes the concept of multiple materials. Namely, each material can have not only distinct material property but also a different level of local porosity, or a combination of both, thus allowing the realization of multiple levels of porosity. With separated density and material/porosity fields, we propose two types of multi-porosity local volume constraints to enable graded porosity considering linear and bi-linear material constitutive relations. Through the proposed framework, single- and multi-material structures can be obtained with a natural transition between the bulk and multiple levels of porous regions. We adopt the Bi-value Coding Parameterization (BCP) scheme combined with the Solid Isotropic Material with Penalization (SIMP) method to interpolate the stored energy functions. Through several examples with multiple porosity levels and various material properties, we demonstrate the effectiveness of the proposed framework with two novel constraints to generate optimized multi-material and multi-porosity structures. We further investigate the interactions among material properties, multiple porosity levels, structural stiffness, and robustness. Compared with conventional bulk designs, the optimized bone-like structures with multi-level graded porosity, although less stiff, are found to be more robust, i.e., their structural stiffness is less influenced by the load variations and material deficiency. The resulting graded porous composite designs showcase the capability of the proposed multi-material formulation to optimize the distributions of not only different types of materials but also multiple levels of porosity.

Research on multi-stage topology optimization method based on latent diffusion model

The high-temperature superconducting magnet (HTS) is one of the core technologies of a superconducting maglev. The effects of multiphysics fields including electromagnetic, mechanical, and thermal should be taken into consideration in design. Traditional design methods rely on the initial configuration and the engineer's experience and only consider the design for the heat conduction performance or the structure strength, which often significantly increases the weight. To solve the above problems, based on COMSOL Multiphysics software, the mathematical model of topology optimization of the main support was established with electromagnetic force and thermal stress as the input loads. The objective functions were assigned to total strain energy and heat leakage, combined with stress value and volume fraction constraint conditions. The solid isotropic material with penalization (SIMP) method was used to carry out the topological analysis of multiphysics. Finally, the innovative structure of main support is obtained. Through finite element analysis of multiphysics fields, the heat leakage, the max Von-Mises stress, and weight were taken as evaluation indexes to compare the optimal structure performance. The results show that the method adopted in this paper can reduce the heat leakage by 61.7% while reducing the weight of the main support by 85%, and the max Von-Mises stress does not exceed the yield limit of the material. The work of this paper provides a theoretical foundation for the engineering design of the heat conduction structure of a HTS magnet.

In this work, topology optimization is used to optimize the compliance or eigenvalues of prestressed plates. The prestress is accounted for by including the force equivalent to the prestressing and adding the initial stress stiffness matrix to the original stiffness matrix. The calculation of the sensitivities is complicated because of the initial stress stiffness matrix, but the computational cost can be kept low by using the adjoint method. The topology optimization problem is solved using the solid isotropic material with penalization (SIMP) method in combination with method of moving asymptotes (MMA). Numerical examples of minimizing compliance or maximizing the first eigenvalue of plates are given. One example is a micro electro mechanical systems (MEMS) application involving a backplate used in a microphone in a hearing aid. Copyright © 2001 John Wiley & Sons, Ltd.

Novel thermal management of electronic devices by nano enhanced phase change materials: A numerical study

In topology optimization of a continuum, it is important to consider stress-related objective or constraints, from both theoretical and application perspectives. It is known that the problem is challenging. Although remarkable achievements have been made with the SIMP (Solid Isotropic Material with Penalization) framework, a number of critical issues are yet to be fully resolved. In the paper, we present an approach of a shape equilibrium constraint strategy with the level-set/X-FEM framework. We formulate the topology optimization problem under (spatially-distributed) stress constraints into a shape equilibrium problem of active stress constraint. This formulation allows us to effectively handle the stress constraint, and the intrinsic non-differentiability introduced by local stress constraints is removed. The optimization problem is made into one of continuous shape-sensitivity and it is solved by evolving a coherent interface of the shape equilibrium concurrently with shape variation in the structural boundary during a level-set evolution process. Several numerical examples in two dimensions are provided as a benchmark test of the proposed shape equilibrium constraint strategy for minimum-weight and fully-stressed designs and for designs with stress constraint satisfaction.

Thermal design of composite cold plates by topology optimization

In this work, an acoustic topology optimization method for structural surface design covered by porous materials is proposed. The analysis of acoustic problems is performed using the isogeometric boundary element method. Taking the element density of porous materials as the design variable, the volume of porous materials as the constraint, and the minimum sound pressure or maximum scattered sound power as the design goal, the topology optimization is carried out by solid isotropic material with penalization (SIMP) method. To get a limpid 0–1 distribution, a smoothing Heaviside-like function is proposed. To obtain the gradient value of the objective function, a sensitivity analysis method based on the adjoint variable method (AVM) is proposed. To find the optimal solution, the optimization problems are solved by the method of moving asymptotes (MMA) based on gradient information. Numerical examples verify the effectiveness of the proposed topology optimization method in the optimization process of two-dimensional acoustic problems. Furthermore, the optimal distribution of sound-absorbing materials is highly frequency-dependent and usually needs to be performed within a frequency band.

Topology optimization (TO) is currently a focal point for researchers in the field of structural optimization, with most studies concentrating on single-loading conditions. However, real engineering structures often have to work under various loading conditions. Approaches addressing multiple-loading conditions often necessitate subjective input in order to determine the importance of each loading condition, aiming for a compromise between them. This paper proposes a so-called bisection constraint method (BCM), offering a unique, user-preference-independent solution for TO problems amidst multiple-loading conditions. It is well-known that minimizing the system’s compliance is commonly used in TO as the objective. Generally, compliance is not as sufficient as stress to be used as a response to evaluate the performance of structures. However, formulations focusing on minimizing stress levels usually pose significant difficulties and instabilities. On the other hand, the compliance approach is generally simpler and more capable of providing relatively sturdy designs. Hence, the formulation of min–max compliance is used as the target problem formulation of the proposed method. This method attempts to minimize compliance under only one loading condition while compliances under the remaining loading conditions are constrained. During the optimization process, the optimization problem is automatically reformulated with a new objective function and a new set of constraint functions. The role of compliance under different loading conditions, i.e., whether it is to be treated as an objective or constraint function, might be changed throughout the optimization process until convergence. Several examples based on the solid isotropic material with penalization (SIMP) approach were conducted to illustrate the validity of the proposed method. Furthermore, the general effectiveness of the compliance approach in terms of stress levels is also discussed. The calculation results demonstrated that while the compliance approach is effective in several cases, it proves ineffective in certain scenarios.