Topology optimization of material nonlinear continuum structures under stress constraints

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.

The effectiveness and efficiency of the bi-directional evolutionary structural optimization (BESO) method has been demonstrated on the problems of minimizing compliance of structures with f ixed external loads. This paper considers the minimization of the mean compliance of continuum structure subjected to design-dependent gravity loads. Due to the non-monotonous behaviour for this type ofthe optimization problems, the extended BESO method using discrete design variables has difficulty in obtaining convergent solutions for such problems. In this paper, a new BESO method is developed based on the sensitivity number computation utilizing an alternative material interpolation scheme. Several examples are presented to demonstrate the capabilities of the proposed method for achieving convergent optimal solutions for structures with design-dependent gravity loads.

Evolutionary topology optimization of continuum structures including design-dependent self-weight loads

A method for the non-probabilistic reliability optimization on frequency of continuum structures with uncertain-but-bounded parameters is proposed. The objective function is to maximize the non-probabilistic reliability index of frequency requirement.The corresponding bi-level optimization model is built, where the constraints are applied on the material volume in the outer loop and the limit state equation in the inner loop. The non-probabilistic reliability index of frequency requirement is derived by the analytical method for the continuum structure with the uncertain elastic module and mass density. Further, the sensitivity of the non-probabilistic reliability index with respect to the design variables is analyzed. The topology optimization in the outer loop is performed by a bi-directional evolutionary structural optimization (BESO) method, where the numerical techniques and the optimization procedure of BESO method are presented. Numerical results show that the proposed BESO method is efficient, and convergent optimal solutions can be achieved for a variety of optimization problems on frequency non-probabilistic reliability of continuum structures.

The evolutionary structural optimization (ESO) method developed by Xie and Steven (Comput Struct 49(5):885–896, 162), an important branch of topology optimization, has undergone tremendous development over the past decades. Among all its variants, the convergent and mesh-independent bi-directional evolutionary structural optimization (BESO) method developed by Huang and Xie (Finite Elem Anal Des 43(14):1039–1049, 48) allowing both material removal and addition, has become a widely adopted design methodology for both academic research and engineering applications because of its efficiency and robustness. This paper intends to present a comprehensive review on the development of ESO-type methods, in particular the latest convergent and mesh-independent BESO method is highlighted. Recent applications of the BESO method to the design of advanced structures and materials are summarized. Compact Malab codes using the BESO method for benchmark structural and material microstructural designs are also provided.

This paper proposes a new bi-directional evolutionary structural optimization (BESO) method with draw direction constraints. Draw direction constraints, defined by required manufacturing process, are achieved by modifying element removal/addition criteria such that elements are removed from the top surface of the draw direction to the inner design domain. The optimized design with draw direction constraints is free from hollow or closed cavity geometries which are infeasible for manufacturing. A stiffness design of a motor front cover is carried out to show the ability of the proposed method in practical mechanical design problems.

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

Evolutionary topology optimization of fiber reinforced composite laminates for maximum stiffness

Concurrent topology optimization of structures and their composite microstructures

Stress-based multi-material structural topology optimization considering graded interfaces

This paper presents a new strategy to distribute two different materials for multi-material topology optimization. Extended from the bi-directional evolutionary structural optimization (BESO) method for a single material, the multi-material bidirectional evolutionary structural optimization (MBESO) method has been developed, which can effectively handle the topology optimization problems involving two materials like steel and concrete. However, in some special cases, overloading of part of the compressed material occurs in the multi-material structures designed by using the MBESO method. Aimed to solve this critical problem, a simple but effective strategy is proposed in this paper. In steel-concrete composite structures, for instance, the overloaded compressed concrete elements with exceedingly high stress are replaced with steel material. The small amount of steel material added to the highly compressed region can effectively reduce the maximum compressive stress of the concrete material to a safe level. The comparison between the original MBESO method and the improved strategy based on a series of two-dimensional and three-dimensional examples clearly demonstrates the effectiveness of the proposed strategy in enhancing the structural safety and strength of the topologically optimized composite structures. This distinctly different material distribution strategy shows its potential and value in multi-material topology optimization research and applications.

Owing to advancement in advanced manufacturing technology, the reinforcement design of concrete structures has become an important topic in structural engineering. Based on bi-directional evolutionary structural optimization (BESO), a new approach is developed in this study to optimize the reinforcement layout in steel-reinforced concrete (SRC) structures. This approach combines a minimum compliance objective function with a hybrid truss-continuum model. Furthermore, a modified bi-directional evolutionary structural optimization (M-BESO) method is proposed to control the level of tensile stress in concrete. To fully utilize the tensile strength of steel and the compressive strength of concrete, the optimization sensitivity of steel in a concrete–steel composite is integrated with the average normal stress of a neighboring concrete. To demonstrate the effectiveness of the proposed procedures, reinforcement layout optimizations of a simply supported beam, a corbel, and a wall with a window are conducted. Clear steel trajectories of SRC structures can be obtained using both methods. The area of critical tensile stress in concrete yielded by the M-BESO is more than 40% lower than that yielded by the uniform design and BESO. Hence, the M-BESO facilitates a fully digital workflow that can be extremely effective for improving the design of steel reinforcements in concrete structures.

ABSTRACTAn underwater glider is a type of autonomous profiling instrument platform used for gathering data to explore the ocean. Having a neutrally buoyant glider hull is one way to improve the glider's endurance with a passive compensation for buoyancy change. This article applies the bi-directional evolutionary structural optimization (BESO) method to the optimization of an underwater glider hull, based on two materials. Firstly, the method for determining the glider's neutral buoyancy is carried out. Secondly, the optimization problem is defined and the optimization procedure is presented. In the BESO procedure, the original design area elements with low strain energy are iteratively switched from high-value materials to low-value materials until a prescribed fraction is reached. Finally, an optimal underwater glider design is generated and the result demonstrates a reasonable material distribution of the neutrally buoyant glider hull. A 26.4% buoyancy adjustment is achieved and the mass of the glider is decreased by 31%.

This paper examines the evolutionary structural optimisation (ESO) method and its shortcomings. By proposing a problem statement for ESO followed by an accurate sensitivity analysis a framework is presented in which ESO is mathematically justifiable. It is shown that when using a sufficiently accurate sensitivity analysis, ESO method is not prone to the problem proposed by Zhou and Rozvany (Struct Multidiscip Optim 21(1):80---83, 2001). A complementary discussion on previous communications about ESO and strategies to overcome the Zhou-Rozvany problem is also presented. Finally it is shown that even the proposed rigorous ESO approach can result in highly inefficient local optima. It is discussed that the reason behind this shortcoming is ESO's inherent unidirectional approach. It is thus concluded that the ESO method should only be used on a very limited class of optimisation problems where the problem's constraints demand a unidirectional approach to final solutions. It is also discussed that the Bidirectional ESO (BESO) method is not prone to this shortcoming and it is suggested that the two methods be considered as completely separate optimisation techniques.

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.