Web Layout Design of Large Cavity Structures Based on Topology Optimization

Large cavity structures are widely employed in aerospace engineering, such as thin-walled cylinders, blades andwings. Enhancing performance of aerial vehicles while reducing manufacturing costs and fuel consumptionhas become a focal point for contemporary researchers. Therefore, this paper aims to investigate the topologyoptimization of large cavity structures as a means to enhance their performance, safety, and efficiency. By usingthe variable density method, lightweight design is achieved without compromising structural strength. Theoptimization model considers both concentrated and distributed loads, and utilizes techniques like sensitivityfiltering and projection to obtain a robust optimized configuration. The mechanical properties are checked bycomparing the stress distribution and displacement of the unoptimized and optimized structures under the sameload. The results confirm that the optimized structures exhibit improved mechanical properties, thus offering keyinsights for engineering lightweight, high-strength large cavity structures.

A Hybrid Level Set Optimization Design Method of Functionally Graded Cellular Structures Considering Connectivity

With the continuous advancement in topology optimization and additive manufacturing(AM)technology,the capability to fabricate functionally graded materials and intricate cellular structures with spatially varying microstructures has grown significantly.However,a critical challenge is encountered in the design of these structures–the absence of robust interface connections between adjacent microstructures,potentially resulting in diminished efficiency or macroscopic failure.A Hybrid Level Set Method(HLSM)is proposed,specifically designed to enhance connectivity among non-uniform microstructures,contributing to the design of functionally graded cellular structures.The HLSM introduces a pioneering algorithm for effectively blending heterogeneous microstructure interfaces.Initially,an interpolation algorithm is presented to construct transition microstructures seamlessly connected on both sides.Subsequently,the algorithm enables the morphing of non-uniform unit cells to seamlessly adapt to interconnected adjacent microstructures.The method,seamlessly integrated into a multi-scale topology optimization framework using the level set method,exhibits its efficacy through numerical examples,showcasing its prowess in optimizing 2D and 3D functionally graded materials(FGM)and multi-scale topology optimization.In essence,the pressing issue of interface connections in complex structure design is not only addressed but also a robust methodology is introduced,substantiated by numerical evidence,advancing optimization capabilities in the realm of functionally graded materials and cellular structures.

Multi-Scale Design and Optimization of Composite Material Structure for Heavy-Duty Truck Protection Device

In this paper,to present a lightweight-developed front underrun protection device(FUPD)for heavy-duty trucks,plain weave carbon fiber reinforced plastic(CFRP)is used instead of the original high-strength steel.First,the mechanical and structural properties of plain carbon fiber composite anti-collision beams are comparatively analyzed from a multi-scale perspective.For studying the design capability of carbon fiber composite materials,we investigate the effects of TC-33 carbon fiber diameter(D),fiber yarn width(W)and height(H),and fiber yarn density(N)on the front underrun protective beam of carbon fiber compositematerials.Based on the investigation,a material-structure matching strategy suitable for the front underrun protective beam of heavy-duty trucks is proposed.Next,the composite material structure is optimized by applying size optimization and stack sequence optimization methods to obtain the higher performance carbon fiber composite front underrun protection beam of commercial vehicles.The results show that the fiber yarn height(H)has the greatest influence on the protective beam,and theH1matching scheme for the front underrun protective beamwith a carbon fiber composite structure exhibits superior performance.The proposed method achieves a weight reduction of 55.21% while still meeting regulatory requirements,which demonstrates its remarkable weight reduction effect.

Design and optimization of fluid lubricated bearings operated with extreme working performances——a comprehensive review

Fluid lubricated bearings have been widely adopted as support components for high-end equipment in metrology,semiconductor devices,aviation,strategic defense,ultraprecision manufacturing,medical treatment,and power generation.In all these applications,the equipment must deliver extreme working performances such as ultraprecise movement,ultrahigh rotation speed,ultraheavy bearing loads,ultrahigh environmental temperatures,strong radiation resistance,and high vacuum operation,which have challenged the design and optimization of reliable fluid lubricated bearings.Breakthrough of any related bottlenecks will promote the development course of high-end equipment.To promote the advancement of high-end equipment,this paper reviews the design and optimization of fluid lubricated bearings operated at typical extreme working performances,targeting the realization of extreme working performances,current challenges and solutions,underlying deficiencies,and promising developmental directions.This paper can guide the selection of suitable fluid lubricated bearings and optimize their structures to meet their required working performances.

Multidisciplinary design optimization of a dual-spin guided vehicle

In this research,a Multidisciplinary Design Optimization approach is proposed for the dual-spin guided flying projectile design considering external and internal parts of the body as design variables.In this way,a parametric formulation is developed.All related disciplines,including structure,aerodynamics,guidance,and control are considered.Minimum total mass,maximum aerodynamic control effectiveness,minimum miss distance,maximum yield stress in all subsystems,controllability and gyroscopic stability constraints are some of objectives/constraints taken into account.The problem is formulated in All-At-Ones Multidisciplinary Design Optimization approach structure and solved by Simulated Annealing and minimax algorithms.The optimal configurations are evaluated in various aspects.The resulted optimal configurations have met all design objectives and constraints.

DYNAMIC RESPONSE OPTIMIZATION DESIGN FOR ENGINEERING STRUCTURES BASED ON RELIABILITY

In many practical structures, physical parameters of material and applied loads have random property.To optimize this kind of structures,an optimum mathematical model was built.This model has reliability constraints on dynamic stress and displacement and upper & lower limits of the design variables. The numerical characteristic of dynamic response and sensitivity of dynamic response based on probability of structure were deduced respectively. By equivalent disposing, the reliability constraints were changed into conventional forms. The SUMT method was used in the optimization process.Two examples illustrate the correctness and practicability of the optimum model and solving approach.

A strategy for lightweight designing of a railway vehicle car body including composite material and dynamic structural optimization

Rolling stock manufacturers are finding structural solutions to reduce power required by the vehicles,and the lightweight design of the car body represents a possible solution.Optimization processes and innovative materials can be combined in order to achieve this goal.In this framework,we propose the redesign and optimization process of the car body roof for a light rail vehicle,introducing a sandwich structure.Bonded joint was used as a fastening system.The project was carried out on a single car of a modern tram platform.This preliminary numerical work was developed in two main steps:redesign of the car body structure and optimization of the innovated system.Objective of the process was the mass reduction of the whole metallic structure,while the constraint condition was imposed on the first frequency of vibration of the system.The effect of introducing a sandwich panel within the roof assembly was evaluated,focusing on the mechanical and dynamic performances of the whole car body.A mass saving of 63%on the optimized components was achieved,corresponding to a 7.6%if compared to the complete car body shell.In addition,a positive increasing of 17.7%on the first frequency of vibration was observed.Encouraging results have been achieved in terms of weight reduction and mechanical behaviour of the innovated car body.

Design and In Situ Additive Manufacturing of Multifunctional Structures

Multifunctional structures(MFSs)integrate diverse functions to achieve superior properties.However,conventional design and manufacturing methods—which generally lack quality control and largely depend on complex equipment with multiple stations to achieve the integration of distinct materials and devices—are unable to satisfy the requirements of MFS applications in emerging industries such as aerospace engineering.Motivated by the concept of design for manufacturing,we adopt a layer regulation method with an established optimization model to design typical MFSs with load-bearing,electric,heat-conduction,and radiation-shielding functions.A high-temperature in situ additive manufacturing(AM)technology is developed to print various metallic wires or carbon fiber-reinforced high-meltingpoint polyetheretherketone(PEEK)composites.It is found that the MFS,despite its low mass,exceeds the stiffness of the PEEK substrate by 21.5%.The embedded electrics remain functional after the elastic deformation stage.Compared with those of the PEEK substrate,the equivalent thermal conductivity of the MFS beneath the central heat source area is enhanced by 568.0%,and the radiation shielding is improved by 27.9%.Moreover,a satellite prototype with diverse MFSs is rapidly constructed as an illustration.This work provides a systematic approach for high-performance design and advanced manufacturing,which exhibits considerable prospects for both the function expansion and performance enhancement of industrial equipment.

AN EFFICIENT ASSESSMENT METHOD FOR INTELLIGENT DESIGN RESULTS OF SHEAR WALL STRUCTURE BASED ON MECHANICAL PERFORMANCE,MATERIAL CONSUMPTION,AND EMPIRICAL RULES

Efficient methods for incorporating engineering experience into the intelligent generation and optimization of shear wall structures are lacking,hindering intelligent design performance assessment and enhancement.This study introduces an assessment method used in the intelligent design and optimization of shear wall structures that effectively combines mechanical analysis and formulaic encoding of empirical rules.First,the critical information about the structure was extracted through data structuring.Second,an empirical rule assessment method was developed based on the engineer's experience and design standards to complete a preliminary assessment and screening of the structure.Subsequently,an assessment method based on mechanical performance and material consumption was used to compare different structural schemes comprehensively.Finally,the assessment effectiveness was demonstrated using a typical case.Compared to traditional assessment methods,the proposed method is more comprehensive and significantly more efficient,promoting the intelligent transformation of structural design.

Crashworthiness Design and Multi-Objective Optimization for Bio-Inspired Hierarchical Thin-Walled Structures

Thin-walled structures have been used in many fields due to their superior mechanical properties.In this paper,two types of hierarchical multi-cell tubes,inspired by the self-similarity of Pinus sylvestris,are proposed to enhance structural energy absorption performance.The finite element models of the hierarchical structures are established to validate the crashworthiness performance under axial dynamic load.The theoreticalmodel of themean crushing force is also derived based on the simplified super folded element theory.The finite element results demonstrate that the energy absorption characteristics and deformation mode of the bionic hierarchical thin-walled tubes are further improved with the increase of hierarchical sub-structures.It can be also obtained that the energy absorption performance of corner self-similar tubes is better than edge self-similar tubes.Furthermore,multiobjective optimization of the hierarchical tubes is constructed by employing the response surface method and genetic algorithm,and the corresponding Pareto front diagram is obtained.This research provides a new idea for the crashworthiness design of thin-walled structures.

Light-Weight Design Method for Force-Performance-Structure of Complex Structural Part Based Co-operative Optimization

A light?weight design method of integrated structural topology and size co?optimization for the force?performance?structure of complex structural parts is presented in this paper. Firstly, the supporting function of a complex structural part is built to map the force transmission, where the force exerted areas and constraints are considered as connecting structure and the structural configuration, to determine the part performance as well as the force routines. Then the connecting structure design model, aiming to optimize the static and dynamic performances on connection configuration, is developed, and the optimum design of the characteristic parameters is carried out by means of the collaborative optimization method, namely, the integrated structural topology optimization and size optimization. In this design model, the objective is to maximize the connecting stiffness. Based on the relationship between the force and the structural configuration of a part, the optimal force transmission routine that can meet the performance requirements is obtained using the structural topology optimization technology. Accordingly, the light?weight design of conceptual configuration for complex parts under multi?objective and multi?condition can be realized. Finally, based on the proposed collaborative optimization design method, the optimal performance and optimal structure of the complex parts with light weight are realized, and the reasonable structural unit configuration and size charac?teristic parameters are obtained. A bed structure of gantry?type machining center is designed by using the proposed light?weight structure design method in this paper, as an illustrative example. The bed after the design optimization is lighter 8% than original one, and the rail deformation is reduced by 5%. Moreover, the lightweight design of the bed is achieved with enhanced performance to show the effectiveness of the proposed method.

Multi-Material and Multiscale Topology Design Optimization of Thermoelastic Lattice Structures

This study establishes amultiscale andmulti-material topology optimization model for thermoelastic lattice structures(TLSs)consideringmechanical and thermal loading based on the ExtendedMultiscale Finite ElementMethod(EMsFEM).The corresponding multi-material and multiscale mathematical formulation have been established with minimizing strain energy and structural mass as the objective function and constraint,respectively.The Solid Isotropic Material with Penalization(SIMP)interpolation scheme has been adopted to realize micro-scale multi-material selection of truss microstructure.The modified volume preserving Heaviside function(VPHF)is utilized to obtain a clear 0/1 material of truss microstructure.Compared with the classic topology optimization of single-material TLSs,multi-material topology optimization can get a better structural design of the TLS.The effects of temperatures,size factor,and mass fraction on optimization results have been presented and discussed in the numerical examples.

Topology optimization of 3D structures with design-dependent loads

Topology optimization of continuum structures with design-dependent loads has long been a challenge. In this paper, the topology optimization of 3D structures subjected to design-dependent loads is investigated. A boundary search scheme is proposed for 3D problems, by means of which the load surface can be identified effectively and efficiently, and the difficulties arising in other approaches can be overcome. The load surfaces are made up of the boundaries of finite elements and the loads can be directly applied to corresponding element nodes, which leads to great convenience in the application of this method. Finally, the effectiveness and efficiency of the proposed method is validated by several numerical examples.

Optimization of the Design of Structures in Coverage Using the Genetic Algorithm Method

In this research work,an optimization of the design of steel structures is developed through Genetic Algorithms(Gas)with the objective of reducing the amount of material and with them the cost,for which the programming of the GAs tool in the Fortran programming language with the SAP2000 Application Programming Interface(API)v.19 using Visual Studio Professional 2015-Intel?Visual Fortran with Parallel Studio XE.The GAs method consists of randomly searching the Objective Function(OF)of the optimal variables with restrictions.The OF defined by the weight of the structure,the variables in relation to the cross sections of the structural elements and the constraints are the design of resistance using the method of Load and Resistance Factor Design(LRFD),restriction of displacements and restriction of the ratio of slenderness considered in the National Building Regulations(RNE),whose GAs search parameters are given by probability of crossing 70%by simple crossing strategy,probability of mutation 20%,elitism of 5%and maximum number of generations according to the profile.The examined metal structure is a cover with five double-body warren arches with 32 m light connected with 24 joists both with welded connections,that is,rigid.The metal structure was evaluated on demand for loads(dead load,live load,snow load,wind load and earthquake loads).The structural design was carried out with the following profiles:circular,tubular,square,angular and Normal Profile with I-shaped section(IPN)of which the most optimal was the tubular profile.The outer diameters of the cross section are:diagonal with a diameter of 1 in,lower flange with a diameter of 23/8 in,upper flange with a diameter of 11/2 in,inner belt with a diameter of 1 in and belt.outside with a diameter of 11/2 in.

Optimization Design of an Embedded Multi-Cell Thin-Walled Energy Absorption Structures with Local Surface Nanocrystallization

Bymeans of the local surface nanocrystallization that enables to change the material on local positions,an innovative embedded multi-cell(EMC)thin-walled energy absorption structures with local surface nanocrystallization is proposed in this paper.The local surface nanacrystallization stripes are regarded as the moving morphable components in the domain for optimal design.Results reveal that after optimizing the local surface nanocrystallization layout,the specific energy absorption(SEA)is increased by 50.78%compared with the untreated counterpart.Besides,in contrast with the optimized 4-cell structure,the SEA of the nanocrystallized embedded 9-cell structure is further enhanced by 27.68%,in contrast with the 9-cell structure,the SEA of the nanocrystallized embedded clapboard type 9-cell structure is enhanced by 3.61%.Thismethod provides a guidance for the design of newenergy absorption devices.

An Overview of Recently Developed Coupled Simulation Optimization Approaches for Reliability Based Minimum Cost Design of Water Retaining Structures

This paper reviews several recently-developed techniques for the minimum-cost optimal design of water-retaining structures (WRSs), which integrate the effects of seepage. These include the incorporation of uncertainty in heterogeneous soil parameter estimates and quantification of reliability. This review is limited to methods based on coupled simulation-optimization (S-O) models. In this context, the design of WRSs is mainly affected by hydraulic design variables such as seepage quantities, which are difficult to determine from closed-form solutions or approximation theories. An S-O model is built by integrating numerical seepage modeling responses to an optimization algorithm based on efficient surrogate models. The surrogate models (meta-models) are trained on simulated data obtained from finite element numerical code solutions. The proposed methodology is applied using several machine learning techniques and optimization solvers to optimize the design of WRS by incorporating different design variables and boundary conditions. Additionally, the effects of several scenarios of flow domain hydraulic conductivity are integrated into the S-O model. Also, reliability based optimum design concepts are incorporated in the S-O model to quantify uncertainty in seepage quantities due to uncertainty in hydraulic conductivity estimates. We can conclude that the S-O model can efficiently optimize WRS designs. The ANN, SVM, and GPR machine learning technique-based surrogate models are efficiently and expeditiously incorporated into the S-O models to imitate the numerical responses of simulations of various problems.

Design and Optimization of Wing Structure for a Fixed-Wing Unmanned Aerial Vehicle (UAV)

The wing, one of the most important parts of aircraft, always requires sophis-ticated design to increase lift, reduce drag and weight. For modern fixed-wing UAV, extending cruising time is always a requirement for the overall design. Designing a most light wing that can match the requirements of work condi-tions is desired. In this work, according to the work conditions, we compare several types of wing and chose beam-type wing. Then we made the detailed design and optimization to reduce the weight of wing. At last, we draw the 3D model for potential realistic production.

基于NAPA Designer的钻台结构参数化设计

钻台作为钻井船或钻井平台中钻井模块的载体,既要满足作业功能的需求,又受到主船体尺度和重量控制等因素的制约,故在初步设计阶段需快速制定不同设计方案供比较选择。在此背景下,该文基于NAPA Designer软件提供的二次开发功能,编写了钻台结构参数化设计模块,通过用户自定义界面数据交互驱动钻台参数化模型的创建和更新,可实现快速提供多种设计方案进行比选,并导出三维有限元模型用于结构强度的分析校核,从而得到钻台结构的优化设计方案。经过实船项目测试表明,基于NAPA Designer软件的钻台结构参数化设计方法可有效降低使用者门槛并显著提高设计效率。

Design of lightweight magnesium car body structure under crash and vibration constraints

Car body design in view of structural performance and lightweighting is a challenging task due to all the performance targets that must be satisfied such as vehicle safety and ride quality.In this paper,material replacement along with multidisciplinary design optimization strategy is proposed to develop a lightweight car body structure that satisfies the crash and vibration criteria while minimizing weight.Through finite element simulations,full frontal,offset frontal,and side crashes of a full car model are evaluated for peak acceleration,intrusion distance,and the internal energy absorbed by the structural parts.In addition,the first three fundamental natural frequencies are combined with the crash metrics to form the design constraints.The wall thicknesses of twenty-two parts are considered as the design variables.Latin Hypercube Sampling is used to sample the design space,while Radial Basis Function methodology is used to develop surrogate models for the selected crash responses at multiple sites as well as the first three fundamental natural frequencies.A nonlinear surrogate-based optimization problem is formulated for mass minimization under crash and vibration constraints.Using Sequential Quadratic Programming,the design optimization problem is solved with the results verified by finite element simulations.The performance of the optimum design with magnesium parts shows significant weight reduction and better performance compared to the baseline design.

Structure optimal design research on backfill hydraulic support

Backfill hydraulic support is the key equipment in achieving coal mining and solid backfilling simultaneously in solid backfill mining technology.Based on the summary and analysis of main types,basic structural properties and filed application of backfill hydraulic support,this work has firstly proposed the basic principle of backfill hydraulic support optimization design and provided the method of optimal design of key structural components,like four-bar linkage,rear canopy and tamping structure;the method is further elaborated as changing hinging position of upper bar to optimize four-bar linkage,by lengthening or shortening the rear canopy to optimize length ratio of canopy;and by changing length and hinging position of tamping structure as well as suspension height of backfill scrape conveyor to realize optimization of tamping structure.On this basis,the process of optimal design of backfill hydraulic support is built.The optimal design case of ZC5200/14.5/30 six columns-four bar linkage used in 7203 W workface of Zhaizhen Coal Mine shows that the backfill properties like horizontal roof gap,vertical horizontal gap,tamping angle and tamping head gap are improved obviously through optimizing four-bar linkage,canopy length and tamping structure according to the optimal design method proposed in this work.