Application of Q4 Strain Gradient Notation Finite Element Method (SGN-FEM) in Level Set Optimization Using Radial Basis Functions

SummaryThe parametric level set approach is an extension of the conventional level set methods for topology optimization. By parameterizing the level set function, level set methods can be directly coupled with mathematical programming to achieve better numerical robustness and computational efficiency. Moreover, the parametric level set scheme can not only inherit the primary advantages of the conventional level set methods, such as clear boundary representation and the flexibility in handling topological changes, but also alleviate some undesired features from the conventional level set methods, such as the need for reinitialization. However, in the existing radial basis function–based parametric level set method, it is difficult to identify the range of the design variables. Besides, the parametric level set evolution often struggles with large fluctuations during the optimization process. Those issues cause difficulties both in numerical stability and in material property mapping. In this paper, a cardinal basis function is constructed based on the radial basis function partition of unity collocation method to parameterize the level set function. The benefit of using cardinal basis function is that the range of the design variables can now be clearly specified as the value of the level set function. A distance regularization energy functional is also introduced, aiming to maintain the desired signed distance property during the level set evolution. With this desired feature, the level set evolution is stabilized against large fluctuations. In addition, the material properties mapped from the level set function to the finite element model can be more accurate.

This thesis aims at understanding and improving topology optimization techniques focusing on density-based level-set methods and geometrical nonlinearities. Central in this work are the numerical modeling of the mechanical response of a design and the consistency of the optimization process itself. Concerning the first topic, we investigate different means to improve the robustness of density-based numerical models including geometrical nonlinearities. The conventional approach (scaling the local material properties) can result in convergence problems due to excessive deformation in low-stiffness finite elements. To avoid excessive deformation, we combine the element connectivity parameterization method (adapting the connectivity between finite elements) with level-set-based topology optimization. Furthermore, we achieve greater robustness of analysis method using a second and improved approach called element deformation scaling. This approach eliminates the need for solving internal equilibrium equations (needed for the element connectivity parameterization method) via an explicit relation between the local internal and global external displacement field. The second focus of this thesis is on the optimization process of level-set-based topology optimization, and in particular its numerical consistency. We observe that signed-distance reinitialization of the level-set function affects the shape of a design in the optimization process. To minimize this effect, we propose a discrete level-set method that is based on an approximate Heaviside function and focusing on the implementation. Furthermore, we also propose a level-set-based topology optimization method using an exact Heaviside function and mathematical programming that effectively eliminates the need for reinitialization. We demonstrate that our density-based level-set method is closely related to conventional density-based topology optimization methods, while offering the advantage of more control over the geometrical complexity. On the other hand, we confirm that the dependence of the final result on the initial design which remains one of the big challenges for level-set-based topology optimization. The potential of the proposed level-set method is shown by applying it on problems with stress constraints and geometrical nonlinearities and performing manufacturing tolerant topology optimization. Finally, this thesis offers a review of level-set methods for structural topology optimization to identify and discuss the different approaches that are available in literature. We can distinguish between level-set methods by examination of their design parameterization, sensitivities, update procedures and regularization techniques. A level-set-based design parameterization offers the advantage of a crisp distinction between subdomains. For this reason, X-FEM approaches and conforming discretizations are an interesting option to retain the crisp nature of the level-set-based description of the design. Many level-set methods are combined with density-based numerical models and are, therefore, closely related to conventional density-based topology optimization methods. In particular, recently proposed projection methods have much in common with a level-set-based design description. The results of level-set-based TO methods often rely heavily on regularization techniques that introduce inconsistencies in the optimization process. Numerical consistency does not necessarily lead to the best search direction, but is essential to find a Karush-Kuhn-Tucker point of the discretized optimization problem.

In conventional level set methods, the slope of the level set function needs to be well controlled to maintain the numerical stability during the topology optimization process. One common solution is to regularize the level set function to be a signed distance function, which is usually achieved by periodically implementing the so called re-initialization scheme to force the level set function to gain the desired signed distance property. However, the re-initialization scheme will bring some unwanted drawbacks to the optimization process, such as zero level set drifting, time consuming etc. In addition, re-initialization is usually implemented outside the optimization loop, which will cause convergence issues. In this paper, a distance regularization functional is introduced to the structural topology optimization objective functional to ensure the signed distance property of the level set function near the structure boundaries. This functional can also keep the level set function to be constant-value at positions far away from the structural boundaries. The radial basis function (RBF) based parameterization technique together with the mathematical programming are utilized to improve the potential capability of handling multiple constraints for the topology optimization. The combination of these two techniques makes the level set based topology optimization be capable of handling complicated multi-constrained problems with higher numerical efficiency, leaving no compromise to multiple drawbacks. To demonstrate the validity of the proposed scheme, benchmark examples on minimum compliance structural optimization are employed. This type of problem is computed by the conventional level set method with the introduced distance regularization functional, the RBF based parametric level set and at last, the distance regularized RBF based parametric level set separately to demonstrate their differences.

Comparing the convected level-set and the Allen–Cahn phase-field methods in AMR/C simulations of two-phase flows

A discontinuous Galerkin finite element method is developed for structural topology optimization with the level set method. The discontinuous Galerkin finite element method is employed to discretize and solve both the elasticity system, possible adjoint, and the transport equation of the level set function. Structural compliance and compliant mechanisms are considered for linear and nonlinear elastic structures. Numerical examples are provided to verify the effectiveness of the algorithm presented.

PurposeShape optimization using the level-set method is one of the most effective automatic design tools for electromagnetic machines. While level-set method has the advantage of being able to suppress unfeasible shape, it has a weakness of being unable to handle complex topology changes such as perforate at material region. With this method, it is only possible to define simple connected topology, and it is difficult to determine the optimal shape which has holes. Therefore, it is important to efficiently expand the searching area in the optimization process with level-set method.Design/methodology/approachIn this paper, the authors introduce the newly defined hole sensitivity which is based on concept of topological derivatives, and combine it with level-set method to effectively create holes in the search process. Furthermore, they consider a variable bandwidth of gray scale, which indicates the transition width between air and magnetic body and combine it with the hole creation method described above. With these methods, the authors aim to expand the searching area in comparison with the conventional level-set method.FindingsAs a result of applying the proposed methods to a magnetic shielding problem, the multi-layered shielding which effectively reduces the magnetic flux in the target area, is successfully produced.Originality/valueThe proposed methods enable us to effectively create a hole and to expand the searching area in the topology optimization process unlike in the case of conventional level-set method.

The structural design must ensure suitable working conditions by attending for safe and economic criteria. However, the optimal solution is not easily available, because these conditions depend on the bodies’ dimensions, materials strength and structural system configuration. In this regard, topology optimization aims for achieving the optimal structural geometry, i.e. the shape that leads to the minimum requirement of material, respecting constraints related to the stress state at each material point. The present study applies an evolutionary approach for determining the optimal geometry of 2D structures using the coupling of the boundary element method (BEM) and the level set method (LSM). The proposed algorithm consists of mechanical modelling, topology optimization approach and structural reconstruction. The mechanical model is composed of singular and hyper-singular BEM algebraic equations. The topology optimization is performed through the LSM. Internal and external geometries are evolved by the LS function evaluated at its zero level. The reconstruction process concerns the remeshing. Because the structural boundary moves at each iteration, the body’s geometry change and, consequently, a new mesh has to be defined. The proposed algorithm, which is based on the direct coupling of such approaches, introduces internal cavities automatically during the optimization process, according to the intensity of Von Mises stress. The developed optimization model was applied in two benchmarks available in the literature. Good agreement was observed among the results, which demonstrates its efficiency and accuracy.

This paper presents some topology optimization results for the designs of flow channels of two-dimensional fields. The numerical method is based on the level set method and the lattice Boltzmann method (LBM). Since the LBM is based on an explicit time integration scheme, it can be used efficiently as the numerical method to calculate the flow field repeatedly in the optimization process. In the conventional approach based on the level set method, the optimum results depends on the choice of the regularization parameter value. In the present paper, numerical tests are performed for a square cavity by changing the value of this regularization parameter.

A boundary element and level set based topology optimisation using sensitivity analysis

Magnetic particles have been being adopted in various areas, ranging from engineering to biomedical fields such as magnetorheological fluids, separation of magnetically tagged DNA, drug delivery and identification of biological species. The particles in a fluid domain can be controlled by an external magnetic field. The magnetized particles also interact between themselves, revealing interesting characteristics. Many theoretical and computational studies have been presented to analyze these characteristics. However, since most of them are based on the point-dipole model, the mutual interaction between the particles has not been taken into account with a high degree of accuracy. In this paper, we propose a new analysis method for particle interaction based on full magnetic field calculation. The particle system is modeled using the finite element method for magnetic field analysis. This is coupled with the level set method that can effectively capture moving geometry of ferromagnetic particles. Numerical results of two test problems of particle chaining and magnetic separation validate this approach for the system dynamics of magnetic particles.

When modeling crack growth in composite materials, one encounters strong (cracks) and weak (material interface) discontinuities. Traditional finite element methods require the mesh to conform to the material interface and crack surface. In addition, costly remeshing is required as crack growth occurs. In this paper, the extended finite element method (XFEM) coupled with the level set method is presented to model both strong and weak discontinuities. For the material interface, an element-based enrichment function is introduced, which shows more consistent behavior than the node-based enrichment function. The XFEM crack implementation and element-based bi-material implementation are validated using analytical solutions.

This study presents a method for constructing a surrogate localization model for a periodic microstructure, or equivalently, a unit cell, to efficiently perform micro-macro coupled analyses of hyperelastic composite materials. The offline process in this approach is to make a response data matrix that stores the microscopic stress distributions in response to various patterns of macroscopic deformation gradients, which is followed by the proper orthogonal decomposition (POD) of the matrix to construct a reduced order model (ROM) of the microscopic analysis (localization) with properly extracted POD bases. Then, response surfaces of the POD coefficients are constructed so that the ROM can be continuous with respect to the input datum, namely, the macroscopic deformation gradient. The novel contributions of this study are the application of the L2 regularization to the interpolation approximations of the POD coefficients by use of radial basis functions (RBFs) to make the response surfaces continuous and the combined use of the cross-validation and the Bayesian optimization to search for the optimal set of parameters in both the RBFs and L2regularization formula. The resulting model can be an alternative to microscopic finite element (FE) analyses in the conventional {text {FE}}^2 method and realizes {text {FE}}^r with 1<r<<2 accordingly. Representative numerical examples of micro-macro coupled analysis with the {text {FE}}^r are presented to demonstrate the capability and promise of the surrogate localization model constructed with the proposed approach in comparison with the results with high-fidelity direct {text {FE}}^2.

Automatic shape optimisation of structural parts driven by BGM and RBF mesh morphing

A method for topology optimization of hinge-free compliant mechanisms with multiple outputs using level set method is presented in this paper. The focus of this paper is on how to prevent generating the flexible hinges during the process of topology optimization of compliant mechanisms. In the proposed method, two types of mean compliances are introduced and built in the proposed multi-objective function for topology optimization of hinge-free compliant mechanisms with multiple outputs, therefore, the spring model widely used for topology optimization of compliant mechanisms is no longer needed. Some numerical examples are presented to illustrate the validity of the proposed method.

SUMMARYThis paper presents a fracture mapping (FM) approach combined with the extended finite element method (XFEM) to simulate coupled deformation and fluid flow in fractured porous media. Specifically, the method accurately represents the impact of discrete fractures on flow and deformation, although the individual fractures are not part of the finite element mesh. A key feature of FM‐XFEM is its ability to model discontinuities in the domain independently of the computational mesh. The proposed FM approach is a continuum‐based approach that is used to model the flow interaction between the porous matrix and existing fractures via a transfer function. Fracture geometry is defined using the level set method. Therefore, in contrast to the discrete fracture flow model, the fracture representation is not meshed along with the computational domain. Consequently, the method is able to determine the influence of fractures on fluid flow within a fractured domain without the complexity of meshing the fractures within the domain. The XFEM component of the scheme addresses the discontinuous displacement field within elements that are intersected by existing fractures. In XFEM, enrichment functions are added to the standard finite element approximation to adequately resolve discontinuous fields within the simulation domain. Numerical tests illustrate the ability of the method to adequately describe the displacement and fluid pressure fields within a fractured domain at significantly less computational expense than explicitly resolving the fracture within the finite element mesh. Copyright © 2013 John Wiley &amp; Sons, Ltd.