Recent Advances on Topology Optimization of Multiscale Nonlinear Structures

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.

This paper will give a short survey about topology optimization of structures. It is particularly focused on topological shape optimization of structures using level-set methods, including the level-set based standard methods and the level-set based alternative methods. The former often directly solve the Hamilton-Jacobi partial differential equation (H-J PDE) to obtain the boundary velocity field using Finite Differential Methods (FDM), and the later commonly employ parametric or equivalent methods to evaluate the velocity field without directly solving the H-J PDE. The unique characteristics of the level-set based topology optimization methods are discussed, and a future perspective and prospects in this research area is also included. A benchmark numerical example is used to showcase the effectiveness of the level-set based methods.

During the last 20 years, structural optimization has become one of the most important topics of engineering applications. Design optimization of structure has been an interesting area of research in the field of engineering design for its ability to short the design cycle and to enhance product quality. Significant research activity has occurred in the area of structural optimization in the last decade. Especially for topology optimization of structure, many new theoretical, algorithmic, and computational contributions have resulted by researchers and engineers. Topology optimization is a powerful tool for global and multi-scale design of macrostructures, microstructures, and the cell of prescribed composite materials. The population based evolutionary algorithms have emerged as powerful mechanism for finding optimum solutions of complex optimization problems in engineering during the last two decades. Evolutionary computation is the study of computational systems which use ideas and get inspiration from natural evolution and adaptation [1]. The thinking has wide application in various engineering fields, such as computer science, artificial intelligence, operations research. Genetic algorithm is another kind of bio-inspired optimization method and it is playing an increasingly important role in studies of complex adaptive systems. Its application ranges from adaptive agents in economic theory to the use of machine learning techniques in the design of complex devices and structures, such as aircraft turbines and integrated circuits [2]. Optimization of structures can be classified into three categories: sizing, shaping, and topology optimization. In the topology optimization, it is concerned with the structure members and connectivity between members. In general, it is easily represented by discrete variables rather than by those used for continuous optimization problems. Topology optimization is the most difficult and complex among three categories and it is special useful in developing innovative conceptual designs. Structural optimization, in particular the topology optimization, has been identified as one of the most challenging tasks in structural design. Various techniques and approaches have been established during the last two decades. Topology optimization usually referred to as layout optimization or general shape optimization [3]. It lets engineers get the optimal topology of structure or new configurations during product design phase, as they are implementing the design of the size

Conventional topology optimization is concerned with the structures modeled by classical theory of mechanics. Since it does not consider the effects of the microstructures of materials, the classical theory can not reveal the size effect due to material’s heterogeneity. Couple-stress theory, which takes account of the microscopic properties of the material, is capable of describing the size effect in deformations. The purpose of this paper is to investigate the formulation for topology optimization of couple-stress material structures. The artificial material density of each element is chosen as design variable. Based on the basic idea of SIMP (Solid Isotropic Material with Penalization) method, the effective material stiffness matrix of couple-stress material is related to the artificial density by power law with penalty. The structural analysis is implemented by finite element method for couple-stress materials, and a 4-noded quadrilateral couple-stress element is formulated in which C1 continuity requirement is relaxed. Some typical problems are solved and the optimal results based on the couple-stress theory are compared with the conventional ones. It is found that the optimal topologies of couple-stress continuum show remarkable size effect.

According to the requirements of the aerospace industry for high strength, high stiffness, and lightweight structural parts, topology optimization has been proved to be an effective product design method. As one of the most conceptual and prospective structural optimization design methods, topology optimization intends to seek the optimal layout of materials in an allowed design region under a given load and boundary conditions. Thus, the object of study in the article is the method of topological optimization of aircraft structures. The goal of this article is to analyze the existing approaches, algorithms, as well as application of the method of topological optimization in the aerospace field in applied problems. The tasks are to describe the existing various approaches methods, features, and research directions of topological optimization as well as to study the possibility of application in the manufacturing process of composite structures. The following results were obtained. The optimization methods are briefly explained and compared, and the advantages and limitations of each approach are discussed. The various ways of simultaneous optimization of fiber orientation and structural topology were described and analyzed. The features of different methods of continuous fiber orientation optimization method were reviewed. The discrete fiber orientation optimization methods were represented. The possibility of multi-scale concurrent topological optimization was described. The combination of topology optimization and additive manufacturing was considered. Finally, the topology optimization of FRC structures which have been resolved in literature are reviewed and the potential research fields requiring more investigation are pointed out. Conclusions. In the article, a comprehensive review of the topology optimization design of FRC structures was presented. The promising way is to combine topology optimization with additive manufacturing techniques. However, these proposed methods may not suitable for other more complex problems, such as bucking stability and natural frequency. Hence, the topology optimization design of complex FRC components under complicated conditions is the main challenge in the future. This can be a new trend in the topology design of FRC structures.

Structural topology optimization.- On basic properties of Michell's structures.- Validation of numerical method by analytical benchmarks and verification of exact solutions by numerical methods.- Introduction to shape and topology optimization.- Homogenization method for shape and topology optimization.- Level set method for shape and topology optimization.- Compliance minimization of two-material elastic structures.- Some notes on topology optimization of vibrating continuum structures.- Topology optimization of vibrating continuum structures for maximum values of simple and multiple eigenfrequencies and frequency gaps.- On optimum shape design and periodicity of band-gape beam structures.- Topological design for minimum dynamic compliance of continuum structures subjected to forced vibration.- Topological design for minimum sound emission from bi-material structures subjected to forced vibration.- Discrete material optimization of vibrating laminated composite plates for minimum sound emission.- Optimization of diffusive transport problems.- Fluid topology optimization: stokes and Navier-stokes models.- Topology optimization of coupled multi-physics problems.- Topology optimization based on the extended finite element method.- Topology optimization of meso- and nano-scale problems.- Topology optimization under uncertainty.- A brief review of numerical methods of structural topology optimization.- The free material design in planar elasticity.

This article proposes an efficient parameterized level set method (PLSM) for structural topology optimization design with minimum compliance as the objective function and volume fraction as the constraint condition. In the stage of establishing the optimization model, the level set function (LSF) is interpolated using compactly-supported radial basis functions (CS-RBFs) to transform the Hamilton-Jacobi partial differential equation (PDE) into ordinary differential equations (ODEs), thereby making the evolution of the LSF more convenient and efficient, and ensuring the smoothness of the optimization result boundary. The method of moving asymptotes (MMA) is used for solving the established optimization model, and meanwhile the shape sensitivity constraint factor is added to improve computational efficiency. During the evolution of the LSF, an approximate re-initialization scheme is employed to prevent the gradient of the LSF boundary from being too large or too small, thereby improving the numerical stability and the convergence speed of structural topology optimization process. Furthermore, the proposed method is also extensible and applicable to topology optimization of multi-material structures. The feasibility and effectiveness of this method have been verified through several typical numerical examples involving topology optimization of single-material structures and multi-material structures within the framework of minimum compliance design. HIGHLIGHTS An efficient parameterized level set method using the approximate re-initialization scheme is proposed for structural topology optimization. The approximate re-initialization scheme is employed when solving the parameterized level set function via the MMA algorithm. This scheme can prevents the gradient of the level set function boundary from being too large or too small, making the level set function update more stable and accelerating the convergence speed of structural topology optimization. The effectiveness and feasibility of the proposed method are demonstrated through examples of single-material and multi-material structural topology optimization.

Isogeometric analysis (IGA) connects CAE with standard CAD design tools and has been utilized for a decade in structural optimization. FEA has a number of drawbacks, including a lack of linkage between analytic and geometric models, a shortage of continuity between components, and a lack of accuracy for high-order elements. Isogeometric analysis effectively overcomes these obstacles. This paper proposes the isogeometric topological optimization mathematical model depending on the asymmetric constitutive relationship of tension and compression microscopic materials. We provide a new density-based topology optimization formulation in which the design domain is limited to the B-spline space. A rectangular domain with a tensor-product is embedded in a design domain that is arbitrarily shaped. The density field is represented using B-splines. The intrinsic filter provided by the B-spline representation for topology optimization is governed by the degrees of B-spline and the knot spans. This B-spline effectively removes numerical artifacts and controls the minimum feature-length in; when the B-spline basis functions span many analysis elements. Benchmark problems in structural topology optimization are computed through Evolutionary Structural Optimization (ESO) algorithm. Comparisons of the optimal structure topologies using finite element analysis and isogeometric collocation methods are analyzed. The influence of different tension-compression stiffness ratios on the final structure topologies is listed and analyzed. The numerical results show the reliability and performance of the proposed mathematical formulation and asymmetry of natural structure.

Structural topology optimization seeks to identify the most efficient way to allocate material within a given domain to achieve a specific design objective. This research area has broad applications in various fields, including mechanical design and other physical disciplines. Over the past two decades, a great variety of applications and diverse research papers on structural topology optimization have been undertaken and published in the last two decades to highlight its acceptance and advantages. This paper presents a scientometric analysis of 5713 papers published between 2000 and 2022 to provide an overview and visualization of the development of structural topology optimization. While there are numerous approaches to topology optimization, this study focuses on presenting a quantitative analysis of the most popular and influential methods. The method used in this paper involved data collection and analysis through CiteSpace, one of the most popular software tools in this field. This paper provides a comprehensive overview of the latest developments of research in structural topology optimization and identifies key directions for future research. The analysis of the top 10 co-cited articles revealed four main approaches that have been developed for structural topology optimization.

Bi-directional evolutionary topology optimization of continuum structures subjected to inertial loads

Topology optimization is the procedure of determining the connectivity, shape and location of voids inside a given design domain. This chapter proposes a quantum-inspired evolutionary algorithm (QEA) for structural topology optimization. It reviews the formulation of the continuum structural topology optimization model and the characteristics of quantum computing. The chapter also proposes the detailed implementation of a QEA-based topology optimization. It discusses two issues: the density-based continuum structural topology optimization formulation and the characteristics of quantum computing, which may be conducive to reducing the computational expense of topology optimization. The entire theoretical procedure of quantum-inspired topology optimization, which mainly combines FEM analysis, design sensitivity solution and quantum-inspired search, is accomplished for continuum structures. As the experimental implementation of quantum computation needs initialization, coherent manipulation, control and read of the fragile quantum system, practically building quantum computers has proved extremely difficult.

Stress-based topology optimization and nonlinear structural topology optimization is gaining increasing attention in order to make topology optimization more realistic. Thus, this paper extends current concepts of topology optimization to the design of structures made of nonlinear materials. An extended bi-directional evolutionary structural optimization (BESO) method for stress minimization topology optimization of material nonlinear structures is proposed in this work. BESO method based on discrete variables can effectively avoid the well-known singularity problem in density-based methods with low-density elements. The maximum von Mises stress is approximated by the p-norm global stress. The sensitivity information for designing variable updates is derived in detail by adjoint method. As for the highly nonlinear stress behavior, the updated scheme takes advantages from two filters respectively of the sensitivity and topological variables to improve convergence. Moreover, the filtered sensitivity numbers are combined with their historical sensitivity information to further stabilize the optimization process. The effectiveness of the proposed method is demonstrated by several 2D benchmark design problems.

This paper deals with topology optimization seen from an industrial and a manufacturing point of view. What the industrial users see as key issues when implementing topology optimization are frequently not the topics that the academic environments consider when implementing topology optimization. One of the key issues is that topology optimization should be integrated into an existing CAD and CAE environment (example of FE-solvers: ABAQUS, ANSYS, CATOPO, NX Nastran, MSc Nastran, MSc Marc and Permas). Here, it is of importance to note that the models analyzed in the industrial CAE environments often consist of many finite elements (can be more than 2 million elements) and different types of elements (continuum, beam, membrane, shell, bar and rigid elements) which all can be employed in the same model. Furthermore, symmetry and manufacturing constraints are important for ensuring that the results of the topology optimized are manufacturable. Several examples will be given of how structural topology optimization can be used as an add-on module in existing CAE environments However, from an academic point of view an add-on module including topology optimization for commercial FE-solvers is also of interest because the latest finite element and solver technology can be applied in the modeling for the topology optimization. Furthermore, the aim is also to show where the industry is today and which demands exist for the future. The results reported here are based upon the work done by FE-Design and their industrial partners using the topology optimization module (TOSCA.topo) and smooth module (TOSCA.smooth) of the program TOSCA.

Material topology optimization is applied to determine the basic layout of a structure. The nonlinear structural response, e.g. buckling or plasticity, must be considered in order to generate a reliable design by structural optimization. In the present paper adaptive material topology optimization is extended to elastoplasticity. The objective of the design problem is to maximize the structural ductility which is defined by the integral of the strain energy over a given range of a prescribed displacement. The mass in the design space is prescribed. The design variables are the densities of the finite elements. The optimization problem is solved by a gradient based OC algorithm. An elastoplastic von Mises material with linear, isotropic work-hardening/softening for small strains is used. A geometrically adaptive optimization procedure is applied in order to avoid artificial stress singularities and to increase the numerical efficiency of the optimization process. The geometric parametrization of the design model is adapted during the optimization process. Elastoplastic structural analysis is outlined. An efficient algorithm is introduced to determine the gradient of the ductility with respect to the densities of the finite elements. The overall optimization procedure is presented and verified with design problems for plane stress conditions.

The finite-volume theory has shown to be numerically efficient and stable for topology optimization of continuum elastic structures. The significant features of this numerical technique are the local satisfaction of equilibrium equations and the employment of compatibility conditions along edges in a surface-averaged sense. These are essential properties to adequately mitigate some numerical instabilities in the gradient version of topology optimization algorithms, such as checkerboard, mesh dependence, and local minima issues. Several computational tools have been proposed for topology optimization employing analysis domains discretized with essential features for finite-element approaches. However, this is the first contribution to offer a platform to generate optimized topologies by employing a Matlab code based on the finite-volume theory for compliance minimization problems. The Top2DFVT provides a platform to perform 2D topology optimization of structures in Matlab, from domain initialization for structured meshes to data post-processing. This contribution represents a significant advancement over earlier publications on topology optimization based on the finite-volume theory, which needed more efficient computational tools. Moreover, the Top2DFVT algorithm incorporates SIMP and RAMP material interpolation schemes alongside sensitivity and density filtering techniques, culminating in a notably enhanced optimization tool. The application of this algorithm to various illustrative cases confirms its efficacy and underscores its potential for advancing the field of structural optimization.