Structural optimization with static aeroelastic and stress constraints using expandable modal basis

This paper describes a method for structural optimization considering the elastoplastic structural behaviour. The proposed method consists of three parts : elastoplastic incremental structural analysis, elastoplastic sensitivity analysis, and optimization. The structural analysis and sensitivity analysis are performed using the incremental finite element method. For structural optimization, the Sequential Unconstrained Minimization Technique (SUMT) is used.In the optimization process, reanalysis is performed using the elastoplastic sensitivities. To get rational reanalysis solutions, some limitations should be imposed on the magnitude of changes in design variables. The maximum allowable changes in design variables are automatically evaluated by applying repeated sensitivity analysis during the optimization process.After verifying the accuracy of the reanalysis solution based on repeated sensitivity analysis, a three-bar and a ten-bar plane trusses are analyzed taking the cross-sectional areas as design variables. Comparison of the results shows that the proposed method gives very good results.

Multidisciplinary design optimization (MDO) is expected to play a major role in the competitive transportation industries of tomorrow, i.e., in the design of aircraft and spacecraft, of high speed trains, boats, and automobiles. All of these vehicles require maximum performance at minimum weight to keep fuel consumption low and conserve resources. Here, MDO can deliver mathematically based design tools to create systems with optimum performance subject to the constraints of disciplines such as structures, aerodynamics, controls, etc. Although some applications of MDO are beginning to surface, the key to a widespread use of this technology lies in the improvement of its efficiency. This aspect is investigated here for the MDO subset of structural optimization, i.e., for the weight minimization of a given structure under size, strength, and displacement constraints. Specifically, finite element based multilevel optimization of structures (here, statically indeterminate trusses and beams for proof of concept) is performed. In the system level optimization, the design variables are the coefficients of assumed displacement functions, and the load unbalance resulting from the solution of the stiffness equations is minimized. Constraints are placed on the deflection amplitudes and the weight of the structure. In the subsystems level optimizations, the weight of each element is minimized under the action of stress constraints, with the cross sectional dimensions as design variables. This approach is expected to prove very efficient, especially for complex structures, since the design task is broken down into a large number of small and efficiently handled subtasks, each with only a small number of variables. This partitioning will also allow for the use of parallel computing, first, by sending the system and subsystems level computations to two different processors, ultimately, by performing all subsystems level optimizations in a massively parallel manner on separate processors. It is expected that the subsystems level optimizations can be further improved through the use of controlled growth, a method which reduces an optimization to a more efficient analysis with only a slight degradation in accuracy. The efficiency of all proposed techniques is being evaluated relative to the performance of the standard single level optimization approach where the complete structure is weight minimized under the action of all given constraints by one processor and to the performance of simultaneous analysis and design which combines analysis and optimization into a single step. It is expected that the present approach can be expanded to include additional structural constraints (buckling, free and forced vibration, etc.) or other disciplines (passive and active controls, aerodynamics, etc.) for true MDO.

<div class="section abstract"><div class="htmlview paragraph">The design of drive units in electric vehicles (EVs) presents challenges due to the need to pass multiple linear and non-linear load cases. This can result in inefficient design. Therefore, optimization plays a critical role in improving the design efficiency. However, setting up the optimization process itself can be challenging, especially when dealing with complex design variables and different load cases that require the use of various computer-aided engineering (CAE) solvers. The drive unit, being a casting component, presents additional challenges in setting up Multidisciplinary Design Optimization (MDO) process. This paper introduces an efficient process for addressing these challenges by presenting a sample Multidisciplinary Design Optimization (MDO) problem. The problem involves the manipulation of discrete design variables, such as the number of ribs, and incorporates five different load cases that require the utilization of different CAE solvers. The proposed process demonstrates a streamlined approach that can be completed in less than one week. It showcases the steps involved in setting up the optimization process, including defining the design variables, selecting appropriate load cases, and integrating different CAE solvers. By following this process, engineers can effectively optimize the design of drive units in EVs, leading to improved mass efficiency. Overall, this paper highlights the importance of optimization in addressing the challenges associated with the design of drive units in EVs. It presents a practical and efficient process that can be implemented within a short timeframe, allowing engineers to achieve optimal design solutions. By leveraging this approach, manufacturers can enhance the performance and efficiency of EV drive units, contributing to the advancement of electric mobility.</div></div>

Optimum design of structures with stress and displacement constraints using the force method

Two-stage local optimization of lattice type support structures for offshore wind turbines

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.

on multidisciplinary design optimization (MDO) of truss-braced wing airplanes. The primary focus has been to include utter constraints for structural sizing of the wing. The structural sizing uses a gradient-based optimization procedure along with an analytically calculated response function sensitivity with respect to the thickness design variables. It is shown that using the updated routine leads to lower structural mass in comparison with the fully-stressed structural design procedure used in the previous MDO studies. The primary reasons for the lower mass is that inertial weight relief due to secondary structure is now included in the sizing process, and the buckling analysis is now based on a linearized eigenvalue problem, as opposed to a simple beam Euler buckling criteria used for the previous study which was signicantly conservative. However, the results show that for a wing with lower mass the utter constraint becomes active for both strut-braced and truss-braced wing congurations. Hence, it is important to include those in the MDO studies to maintain feasibility of designs. Two challenges encountered during the process of including structural optimization with the utter constraint within the system-level MDO architecture are discussed along with the strategies devised to overcome them: convergence of structural optimization and the resulting numerical noise. A response surface methodology is used to integrate the structural optimization and system-level MDO and some initial results for the design of a truss-braced wing transonic transport airplane for minimum fuel consumption and emissions are presented.

Model-Based Systems Engineering (MBSE) supports the system-level design of complex products effectively. Currently, system design and optimization for complex products are two distinct processes that must be executed using different software or platforms, involving intricate data conversion processes. Applying multidisciplinary optimization to validate system optimization often necessitates remodeling the optimization objects, which is time-consuming, labor-intensive, and highly error-prone. A critical activity in systems engineering is identifying the optimal design solution for the entire system. Multidisciplinary Design Optimization (MDO) and reliability analysis are essential methods for achieving this. This paper proposes a SysML-based multidisciplinary reliability design optimization modeling method. First, by analyzing the definitions and mathematical models of multidisciplinary reliability design optimization, the SysML extension mechanism is employed to represent the optimization model based on SysML. Next, model transformation techniques are used to convert the SysML optimization model generated in the first stage into an XML description model readable by optimization solvers. Finally, the proposed method’s effectiveness is validated through an engineering case study of an in-vehicle environmental control integration system. The results demonstrate that this method fully utilizes SysML to express MDO problems, enhancing the efficiency of design optimization for complex systems. Engineers and system designers working on complex, multidisciplinary projects can particularly benefit from these advancements, as they simplify the integration of design and optimization processes, facilitating more reliable and efficient product development.

The optimization of the large structure with the layout of stiffener is considered by a new calculation method in this study. Many number of stiffener are attached to large structures. Optimization of the large structures with design variables of plate thickness and shape of stiffener is performed. However, in order to obtain a better optimal solution, the optimization of the structure with design variable of number of stiffener and allocation of stiffener is required. But, the optimization of structure with design variable of the number of stiffener and allocation of stiffener is not performed. There are two problems. The first problem is the FEM model. FEM models need some nodes at allocation of stiffener as a characteristic of FEM. When number of stiffener and allocation of stiffener are changed by the process of the optimization of the structure, number of nodes and allocation of nodes of FEM model is also changed. Therefore, in order to ensure consistency of mesh, it is necessary to remake FEM model. In order to optimize structural, it is necessary to examine many propositions for design. However it is difficult to create and analyze the proposition for design of many numbers in restricted time. The second problem is the optimization method. When the number and allocate of stiffeners are changed, the stricture is modified and the number of design variables is changed. The optimization problem with changed number of design variables cannot be optimized by standard optimization methods. The methods of solving these problems are examined.

<div class="htmlview paragraph">In this paper the development of statistical metamodels and statistical fast running models is presented first. They are utilized for propagating uncertainties in a multi-discipline design optimization process. Two main types of uncertainty can be considered in this manner: uncertainty due to variability in design variables or in random parameters; uncertainty due to the utilization of metamodels instead of the actual simulation models during the optimization process. The value of the new developments and their engagement in multi-discipline design optimization is demonstrated through a case study. An underwater vehicle is designed under four different disciplines, namely, noise radiation, self-noise due to TBL excitation, dynamic response due to propulsion impact loads, and response to an underwater detonation. The case study also demonstrates the value of the multi-discipline design optimization in identifying a system level optimum, and it emphasizes the importance of including uncertainties in the design optimization process.</div>

This paper discusses the integrated topology and sizing optimization of frame structures where beam elements are used in the structural analysis model. Based on the ground structure approach, discrete variables (0, 1) representing the absence or presence of beam members and continuous sizing variables for beam cross sections are involved in the problem. A two-level multipoint approximation strategy is introduced to address this mixed-variable problem. A first-level approximate problem is first constructed using the branched multipoint approximate function involving both discrete and continuous variables. For solving this problem, discrete variables are optimized through a genetic algorithm, and when calculating the fitness in the genetic algorithm, a second-level approximate problem solved by the dual method is established to optimize the cross sections for the retained beam members. Temporal deletion techniques are used for displacement and stress constraints. Meanwhile, by considering local vibration modes in frequency-constrained problems, material density is assigned with an extremely small value for the removed beams to avoid these local modes. Thence, the singularities encountered in stress, displacement, and frequency constraints are overcome. Typical examples and a satellite application are given to verify the feasibility and efficiency of this method in handling the integrated topology and sizing optimization for frame structures.

In order to design a vehicle body with high strength and high stiffness, a multi-disciplinary design process should include careful consideration of multi-disciplinary design constraints to properly account for vehicle static stiffness (bending/torsional), durability, Noise/Vibration/Harshness (NVH), crash worthiness, light weight vehicle structure during the early stage of vehicle design process. With this approach, fast development of new vehicle body structures can be achieved with minimal number of iterations to match the conflicting design goals from each discipline. In the current research, a multi-disciplinary design optimization (MDO) based on a meta model is developed and refined to apply for the design of body structure. In an effort to apply the MDO for vehicle body structure, 4 phase procedures were established in the current research. In Phase I, a base model is created. In Phase II, an effect analysis is carried out. In Phase III, a meta model is created. Finally in Phase IV, using the optimization algorithm, the meta model created in Phase III is eventually refined through the process of optimization. In this research, static stiffness (bending / torsional), dynamic stiffness (1st torsion mode) were used for constrained conditions and the mass minimization was the object function for optimization.

A desirable feature in multidisciplinary design optimization (MDO) is to achieve an acceptable preliminary or initial design in an expeditiously fashion. One way to pursue this goal is to describe the structural boundary using a small number of design variables. In this paper we propose an approach to structural optimization that enhances the performance of multidisciplinary design tools because it greatly decreases the number of design variables assigned to structural deflnition. This approach is based on the Level Set Methods and uses the coe‐cients of the Fourier series expansion of the level set function as design variables. The global character of these coe‐cients and the fact that the level set function is real-valued provide the means to reduce the design space dimension. Within the level set framework, the structure is conflned to the region in which the level set function is negative. In this way, the zero level set of this function implicitly describes the structural boundary, which can undergo topological changes during the optimization process as the function evolves. The proposed methodology also averts successive mesh generation. We show that an interface can be described to any desirable accuracy using flnitely many Fourier modes of the signed distance to the interface. The total error is inversely proportional to the number of Fourier modes. We present two validation examples in topology optimization, and use these cases to study the efiects of the methodology parameters on the results. Finally, we propose two examples of application to the enhancement of aircraft roll maneuvers. In the flrst, the goal is to determine the layout of reinforcements in the front spar of a wing-aileron that maximizes the aileron reversal speed, subject to a constraint in the amount of reinforcing material. We also propose the design of a morphing airfoil-aileron conflguration capable of changing its mean camber to maximize the aileron efiectiveness through the activation of a system of actuators, given a restriction on power consumption.

The modal-based aeroelastic optimization approach is reformulated and extended such that it can deal with more structural analysis and optimization features. The disciplines treated in this paper are statics under fixed loads and static aeroelasticity of free-free aircraft. The new formulation includes the application of stress constraints under fixed and varied external loads, and the effects of inertial changes on aeroelastic trim. It also facilitates the integration of the modal-based option in common finite element structural optimization schemes. The new scheme is applied to realistic design cases using the multidisciplinary automated structural optimization system ASTROS code. Application cases of 3761 and 26,259 degrees of freedom exhibit CPU time reduction factors of 4-122 in comparison with the conventional discrete approach.

<p>Multidisciplinary design optimization (MDO) refers to the process of designing systems characterized by the interaction of multiple interconnected disciplines. High-fidelity MDO usually requires large computational resources due to the computational cost of achieving multidisciplinary consistent solutions by coupling high-fidelity physics-based solvers. Gradient-based minimization algorithms are generally applied to find local minima, due to their efficiency in solving problems with a large number of design variables. This represents a limitation to performing global MDO and integrating black-box type analysis tools, usually not providing gradient information. The latter issues generally inhibit a wide use of MDO in complex industrial applications.</p><p>An architecture named multi-criterion adaptive sampling MDO (MCAS-MDO) is presented in the current research for complex simulation-based applications. This research aims at building a global derivative-free optimization tool able to employ high-fidelity/expensive black-box solvers for the analysis of the disciplines. MCAS-MDO is a surrogate-based architecture featuring a variable level of coupling among the disciplines and is driven by a multi-criterion adaptive sampling (MCAS) assessing coupling and sampling uncertainties. MCAS uses the dynamic radial basis function surrogate model to identify the optimal solution and explore the design space through parallel infill of new solutions.</p><p>The MCAS-MDO is tested versus a global derivative-free multidisciplinary feasible (MDF) approach, which solves fully-coupled multidisciplinary analyses, for two analytical test problems. Evaluation metrics include number of function evaluations required to achieve the optimal solution and sample distribution. The MCAS-MDO outperforms the MDF showing a faster convergence by clustering refined function evaluations in the optimum region.</p><p>The architecture is applied to a steady fluid-structure interaction (FSI) problem, namely the design of a tapered three-dimensional carbon fiber-reinforced plastic hydrofoil for minimum drag. The objective is the design of shape and composite material layout subject to hydrodynamic, structural, and geometrical constraints. Experimental data are available for the original configuration of the hydrofoil and allow validating the FSI analysis, which is performed coupling computational fluid dynamics, solving the Reynolds averaged Navier-Stokes equations, and finite elements, solving the structural equation of elastic motion. Hydrofoil forces, tip displacement, and tip twist are evaluated for several materials providing qualitative agreement with the experiments and confirming the need for the two-way versus one-way coupling approach in case of significantly compliant structures.</p><p>The free-form deformation method is applied to generate shape modifications of the hydrofoil geometry. To reduce the global computational expense of the optimization, a design space assessment and dimensionality reduction based on the Karhunen–Loève expansion (KLE) is performed off-line, i.e. without the need for high-fidelity simulations. It provides with a selection of design variables for the problem at hand through basis rotation and re-parametrization. By using the KLE, an efficient design space is identified for the current problem and the number of design variables is reduced by 92%.</p><p>A sensitivity analysis is performed prior to the optimization to assess the variability associated with the shape design variables and the composite material design variable, i.e. the fiber orientation. These simulations are used to initialize the surrogate model for the optimization, which is carried out for two models: one in aluminum and one in composite material. The optimized designs are assessed by comparison with the original models through evaluation of the flow field, pressure distribution on the body, and deformation under the hydrodynamic load. The drag of the aluminum and composite material hydrofoils is reduced by 4 and 11%, respectively, increasing the hydrodynamic efficiency by 4 and 7%. The optimized designs are obtained by evaluating approximately 100 designs. The quality of the results indicates that global derivative-free MDO of complex engineering applications using expensive black-box solvers can be achieved at a feasible computational cost by minimizing the design space dimensionality and performing an intelligent sampling to train the surrogate-based optimization.</p>