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.

Multi-Material Topology Optimization for Spatial-Varying Porous Structures

This paper aims to propose a topology optimization method on generating porous structures comprising multiple materials.The mathematical optimization formulation is established under the constraints of individual volume fraction of constituent phase or total mass,as well as the local volume fraction of all phases.The original optimization problem with numerous constraints is converted into a box-constrained optimization problem by incorporating all constraints to the augmented Lagrangian function,avoiding the parameter dependence in the conventional aggregation process.Furthermore,the local volume percentage can be precisely satisfied.The effects including the globalmass bound,the influence radius and local volume percentage on final designs are exploited through numerical examples.The numerical results also reveal that porous structures keep a balance between the bulk design and periodic design in terms of the resulting compliance.All results,including those for irregular structures andmultiple volume fraction constraints,demonstrate that the proposedmethod can provide an efficient solution for multiple material infill structures.

A Subdivision-Based Combined Shape and Topology Optimization in Acoustics

We propose a combined shape and topology optimization approach in this research for 3D acoustics by using the isogeometric boundary element method with subdivision surfaces.The existing structural optimization methods mainly contain shape and topology schemes,with the former changing the surface geometric profile of the structure and the latter changing thematerial distribution topology or hole topology of the structure.In the present acoustic performance optimization,the coordinates of the control points in the subdivision surfaces fine mesh are selected as the shape design parameters of the structure,the artificial density of the sound absorbing material covered on the structure surface is set as the topology design parameter,and the combined topology and shape optimization approach is established through the sound field analysis of the subdivision surfaces boundary element method as a bridge.The topology and shape sensitivities of the approach are calculated using the adjoint variable method,which ensures the efficiency of the optimization.The geometric jaggedness and material distribution discontinuities that appear in the optimization process are overcome to a certain degree by the multiresolution method and solid isotropic material with penalization.Numerical examples are given to validate the effectiveness of the presented optimization approach.

An Overview of Sequential Approximation in Topology Optimization of Continuum Structure

This paper offers an extensive overview of the utilization of sequential approximate optimization approaches in the context of numerically simulated large-scale continuum structures.These structures,commonly encountered in engineering applications,often involve complex objective and constraint functions that cannot be readily expressed as explicit functions of the design variables.As a result,sequential approximation techniques have emerged as the preferred strategy for addressing a wide array of topology optimization challenges.Over the past several decades,topology optimization methods have been advanced remarkably and successfully applied to solve engineering problems incorporating diverse physical backgrounds.In comparison to the large-scale equation solution,sensitivity analysis,graphics post-processing,etc.,the progress of the sequential approximation functions and their corresponding optimizersmake sluggish progress.Researchers,particularly novices,pay special attention to their difficulties with a particular problem.Thus,this paper provides an overview of sequential approximation functions,related literature on topology optimization methods,and their applications.Starting from optimality criteria and sequential linear programming,the other sequential approximate optimizations are introduced by employing Taylor expansion and intervening variables.In addition,recent advancements have led to the emergence of approaches such as Augmented Lagrange,sequential approximate integer,and non-gradient approximation are also introduced.By highlighting real-world applications and case studies,the paper not only demonstrates the practical relevance of these methods but also underscores the need for continued exploration in this area.Furthermore,to provide a comprehensive overview,this paper offers several novel developments that aim to illuminate potential directions for future research.

Ballistic performance of additive manufacturing 316l stainless steel projectiles based on topology optimization method

Material and structure made by additive manufacturing(AM)have received much attention lately due to their flexibility and ability to customize complex structures.This study first implements multiple objective topology optimization simulations based on a projectile perforation model,and a new topologic projectile is obtained.Then two types of 316L stainless steel projectiles(the solid and the topology)are printed in a selective laser melt(SLM)machine to evaluate the penetration performance of the projectiles by the ballistic test.The experiment results show that the dimensionless specific kinetic energy value of topologic projectiles is higher than that of solid projectiles,indicating the better penetration ability of the topologic projectiles.Finally,microscopic studies(scanning electron microscope and X-ray micro-CT)are performed on the remaining projectiles to investigate the failure mechanism of the internal structure of the topologic projectiles.An explicit dynamics simulation was also performed,and the failure locations of the residual topologic projectiles were in good agreement with the experimental results,which can better guide the design of new projectiles combining AM and topology optimization in the future.

Topology Optimization of Two Fluid Heat Transfer Problems for Heat Exchanger Design

Topology optimization of thermal-fluid coupling problems has received widespread attention.This article proposes a novel topology optimization method for laminar two-fluid heat exchanger design.The proposed method utilizes an artificial density field to create two permeability interpolation functions that exhibit opposing trends,ensuring separation between the two fluid domains.Additionally,a Gaussian function is employed to construct an interpolation function for the thermal conductivity coefficient.Furthermore,a computational program has been developed on the OpenFOAM platform for the topology optimization of two-fluid heat exchangers.This program leverages parallel computing,significantly reducing the time required for the topology optimization process.To enhance computational speed and reduce the number of constraint conditions,we replaced the conventional pressure drop constraint condition in the optimization problem with a pressure inlet/outlet boundary condition.The 3D optimization results demonstrate the characteristic features of a surface structure,providing valuable guidance for designing heat exchangers that achieve high heat exchange efficiency while minimizing excessive pressure loss.At the same time,a new structure appears in large-scale topology optimization,which proves the effectiveness and stability of the topology optimization program written in this paper in large-scale calculation.

Dynamic Resistance and Energy Absorption of Sandwich Beam via a Micro-Topology Optimization

The current research of sandwich structures under dynamic loading mainly focus on the response characteristic of structure.The micro-topology of core layers would sufficiently influence the property of sandwich structure.However,the micro deformation and topology mechanism of structural deformation and energy absorption are unclear.In this paper,based on the bi-directional evolutionary structural optimization method and periodic base cell(PBC)technology,a topology optimization frame work is proposed to optimize the core layer of sandwich beams.The objective of the present optimization problem is to maximize shear stiffness of PBC with a volume constraint.The effects of the volume fraction,filter radius,and initial PBC aspect ratio on the micro-topology of the core were discussed.The dynamic response process,core compression,and energy absorption capacity of the sandwich beams under blast impact loading were analyzed by the finite element method.The results demonstrated that the overpressure action stage was coupled with the core compression stage.Under the same loading and mass per unit area,the sandwich beam with a 20%volume fraction core layer had the best blast resistance.The filter radius has a slight effect on the shear stiffness and blast resistances of the sandwich beams.But increasing the filter radius could slightly improve the bending stiffness.Upon changing the initial PBC aspect ratio,there are three ways for PBC evolution:The first is to change the angle between the adjacent bars,the second is to further form holes in the bars,and the third is to combine the first two ways.However,not all three ways can improve the energy absorption capacity of the structure.Changing the aspect ratio of the PBC arbitrarily may lead to worse results.More studies are necessary for further detailed optimization.This research proposes a new topology sandwich beam structure by micro-topology optimization,which has sufficient shear stiffness.The micro mechanism of structural energy absorption is clarified,it is significant for structural energy absorption design.

A non-probabilistic reliability topology optimization method based on aggregation function and matrix multiplication considering buckling response constraints

A non-probabilistic reliability topology optimization method is proposed based on the aggregation function and matrix multiplication.The expression of the geometric stiffness matrix is derived,the finite element linear buckling analysis is conducted,and the sensitivity solution of the linear buckling factor is achieved.For a specific problem in linear buckling topology optimization,a Heaviside projection function based on the exponential smooth growth is developed to eliminate the gray cells.The aggregation function method is used to consider the high-order eigenvalues,so as to obtain continuous sensitivity information and refined structural design.With cyclic matrix programming,a fast topology optimization method that can be used to efficiently obtain the unit assembly and sensitivity solution is conducted.To maximize the buckling load,under the constraint of the given buckling load,two types of topological optimization columns are constructed.The variable density method is used to achieve the topology optimization solution along with the moving asymptote optimization algorithm.The vertex method and the matching point method are used to carry out an uncertainty propagation analysis,and the non-probability reliability topology optimization method considering buckling responses is developed based on the transformation of non-probability reliability indices based on the characteristic distance.Finally,the differences in the structural topology optimization under different reliability degrees are illustrated by examples.

Probabilistic-Ellipsoid Hybrid Reliability Multi-Material Topology Optimization Method Based on Stress Constraint

This paper proposes a multi-material topology optimization method based on the hybrid reliability of the probability-ellipsoid model with stress constraint for the stochastic uncertainty and epistemic uncertainty of mechanical loads in optimization design.The probabilistic model is combined with the ellipsoidal model to describe the uncertainty of mechanical loads.The topology optimization formula is combined with the ordered solid isotropic material with penalization(ordered-SIMP)multi-material interpolation model.The stresses of all elements are integrated into a global stress measurement that approximates the maximum stress using the normalized p-norm function.Furthermore,the sequential optimization and reliability assessment(SORA)is applied to transform the original uncertainty optimization problem into an equivalent deterministic topology optimization(DTO)problem.Stochastic response surface and sparse grid technique are combined with SORA to get accurate information on the most probable failure point(MPP).In each cycle,the equivalent topology optimization formula is updated according to the MPP information obtained in the previous cycle.The adjoint variable method is used for deriving the sensitivity of the stress constraint and the moving asymptote method(MMA)is used to update design variables.Finally,the validity and feasibility of the method are verified by the numerical example of L-shape beam design,T-shape structure design,steering knuckle,and 3D T-shaped beam.

Multi-Material Topology Optimization of 2D Structures Using Convolutional Neural Networks

In recent years,there has been significant research on the application of deep learning(DL)in topology optimization(TO)to accelerate structural design.However,these methods have primarily focused on solving binary TO problems,and effective solutions for multi-material topology optimization(MMTO)which requires a lot of computing resources are still lacking.Therefore,this paper proposes the framework of multiphase topology optimization using deep learning to accelerate MMTO design.The framework employs convolutional neural network(CNN)to construct a surrogate model for solving MMTO,and the obtained surrogate model can rapidly generate multi-material structure topologies in negligible time without any iterations.The performance evaluation results show that the proposed method not only outputs multi-material topologies with clear material boundary but also reduces the calculation cost with high prediction accuracy.Additionally,in order to find a more reasonable modeling method for MMTO,this paper studies the characteristics of surrogate modeling as regression task and classification task.Through the training of 297 models,our findings show that the regression task yields slightly better results than the classification task in most cases.Furthermore,The results indicate that the prediction accuracy is primarily influenced by factors such as the TO problem,material category,and data scale.Conversely,factors such as the domain size and the material property have minimal impact on the accuracy.

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.

Fiber Bundle Topology Optimization for Surface Flows

This paper presents a topology optimization approach for the surface flows on variable design domains.Via this approach,the matching between the pattern of a surface flow and the 2-manifold used to define the pattern can be optimized,where the 2-manifold is implicitly defined on another fixed 2-manifold named as the base manifold.The fiber bundle topology optimization approach is developed based on the description of the topological structure of the surface flow by using the differential geometry concept of the fiber bundle.The material distribution method is used to achieve the evolution of the pattern of the surface flow.The evolution of the implicit 2-manifold is realized via a homeomorphous map.The design variable of the pattern of the surface flow and that of the implicit 2-manifold are regularized by two sequentially implemented surface-PDE filters.The two surface-PDE filters are coupled,because they are defined on the implicit 2-manifold and base manifold,respectively.The surface Navier-Stokes equations,defined on the implicit 2-manifold,are used to describe the surface flow.The fiber bundle topology optimization problem is analyzed using the continuous adjoint method implemented on the first-order Sobolev space.Several numerical examples have been provided to demonstrate this approach,where the combination of the viscous dissipation and pressure drop is used as the design objective.

Topology Optimization of Metamaterial Microstructures for Negative Poisson’s Ratio under Large Deformation Using a Gradient-Free Method

Negative Poisson’s ratio(NPR)metamaterials are attractive for their unique mechanical behaviors and potential applications in deformation control and energy absorption.However,when subjected to significant stretching,NPR metamaterials designed under small strain assumption may experience a rapid degradation in NPR performance.To address this issue,this study aims to design metamaterials maintaining a targeted NPR under large deformation by taking advantage of the geometry nonlinearity mechanism.A representative periodic unit cell is modeled considering geometry nonlinearity,and its topology is designed using a gradient-free method.The unit cell microstructural topologies are described with the material-field series-expansion(MFSE)method.The MFSE method assumes spatial correlation of the material distribution,which greatly reduces the number of required design variables.To conveniently design metamaterials with desired NPR under large deformation,we propose a two-stage gradient-free metamaterial topology optimization method,which fully takes advantage of the dimension reduction benefits of the MFSE method and the Kriging surrogate model technique.Initially,we use homogenization to find a preliminary NPR design under a small deformation assumption.In the second stage,we begin with this preliminary design and minimize deviations in NPR from a targeted value under large deformation.Using this strategy and solution technique,we successfully obtain a group of NPR metamaterials that can sustain different desired NPRs in the range of[−0.8,−0.1]under uniaxial stretching up to 20% strain.Furthermore,typical microstructure designs are fabricated and tested through experiments.The experimental results show good consistency with our numerical results,demonstrating the effectiveness of the present gradientfree NPR metamaterial design strategy.

A Hybrid Parallel Strategy for Isogeometric Topology Optimization via CPU/GPU Heterogeneous Computing

This paper aims to solve large-scale and complex isogeometric topology optimization problems that consumesignificant computational resources. A novel isogeometric topology optimization method with a hybrid parallelstrategy of CPU/GPU is proposed, while the hybrid parallel strategies for stiffness matrix assembly, equationsolving, sensitivity analysis, and design variable update are discussed in detail. To ensure the high efficiency ofCPU/GPU computing, a workload balancing strategy is presented for optimally distributing the workload betweenCPU and GPU. To illustrate the advantages of the proposedmethod, three benchmark examples are tested to verifythe hybrid parallel strategy in this paper. The results show that the efficiency of the hybrid method is faster thanserial CPU and parallel GPU, while the speedups can be up to two orders of magnitude.

Full-Scale Isogeometric Topology Optimization of Cellular Structures Based on Kirchhoff-Love Shells

Cellular thin-shell structures are widely applied in ultralightweight designs due to their high bearing capacity and strength-to-weight ratio.In this paper,a full-scale isogeometric topology optimization(ITO)method based on Kirchhoff-Love shells for designing cellular tshin-shell structures with excellent damage tolerance ability is proposed.This method utilizes high-order continuous nonuniform rational B-splines(NURBS)as basis functions for Kirchhoff-Love shell elements.The geometric and analysis models of thin shells are unified by isogeometric analysis(IGA)to avoid geometric approximation error and improve computational accuracy.The topological configurations of thin-shell structures are described by constructing the effective density field on the controlmesh.Local volume constraints are imposed in the proximity of each control point to obtain bone-like cellular structures.To facilitate numerical implementation,the p-norm function is used to aggregate local volume constraints into an equivalent global constraint.Several numerical examples are provided to demonstrate the effectiveness of the proposed method.After simulation and comparative analysis,the results indicate that the cellular thin-shell structures optimized by the proposed method exhibit great load-carrying behavior and high damage robustness.

Topology optimization of chiral metamaterials with application to underwater sound insulation

Chiral metamaterials have been proven to possess many appealing mechanical phenomena,such as negative Poisson's ratio,high-impact resistance,and energy absorption.This work extends the applications of chiral metamaterials to underwater sound insulation.Various chiral metamaterials with low acoustic impedance and proper stiffness are inversely designed using the topology optimization scheme.Low acoustic impedance enables the metamaterials to have a high and broadband sound transmission loss(STL),while proper stiffness guarantees its robust acoustic performance under a hydrostatic pressure.As proof-of-concept demonstrations,two specimens are fabricated and tested in a water-filled impedance tube.Experimental results show that,on average,over 95%incident sound energy can be isolated by the specimens in a broad frequency range from 1 k Hz to 5 k Hz,while the sound insulation performance keeps stable under a certain hydrostatic pressure.This work may provide new insights for chiral metamaterials into the underwater applications with sound insulation.

Concurrent Two-Scale Topology Optimization of Thermoelastic Structures Using a M-VCUT Level Set Based Model of Microstructures

By analyzing the results of compliance minimization of thermoelastic structures,we observed that microstructures play an important role in this optimization problem.Then,we propose to use a multiple variable cutting(M-VCUT)level set-based model of microstructures to solve the concurrent two-scale topology optimization of thermoelastic structures.A microstructure is obtained by combining multiple virtual microstructures that are derived respectively from multiple microstructure prototypes,thus giving more diversity of microstructure and more flexibility in design optimization.The effective mechanical properties of microstructures are computed in an off-line phase by using the homogenization method,and then a mapping relationship between the design variables and the effective properties is established,which gives a data-driven model of microstructure.In the online phase,the data-driven model is used in the finite element analysis to improve the computational efficiency.The compliance minimization problem is considered,and the results of numerical examples prove that the proposed method is effective.

Investigation of Liquid Cooling Plate for Server CPUs Based on Topology Optimization

In this study, a microchannel liquid cooling plate (LCP) is proposed for Intel Xeon 52.5 mm * 45 mm packaged architecture processors based on topology optimization (TO). Firstly, a mathematical model for topology optimization design of the LCP is established based on heat dissipation and pressure drop objectives. We obtain a series of two-dimensional (2D) topology optimization configurations with different weighting factors for two objectives. It is found that the biomimetic phenomenon of the topologically optimized flow channel structure is more pronounced at low Reynolds numbers. Secondly, the topology configuration is stretched into a three-dimensional (3D) model to perform CFD simulations under actual operating conditions. The results show that the thermal resistance and pressure drop of the LCP based on topology optimization achieve a reduction of approximately 20% - 50% compared to traditional serpentine and microchannel straight flow channel structures. The Nusselt number can be improved by up to 76.1% compared to microchannel straight designs. Moreover, it is observed that under high flow rates, straight microchannel LCPs exhibit significant backflow, vortex phenomena, and topology optimization structures LCPs also tend to lead to loss of effectiveness in the form of tree root-shaped branch flows. Suitable flow rate ranges for LCPs are provided. Furthermore, the temperature and pressure drop of experimental results are consistent with the numerical ones, which verifies the effectiveness of performance for topology optimization flow channel LCP.

The Topology Optimization of Oil Cylinder Mounting

The method of the structural topology optimization is often used to design machine in the early stage of the mechanical design.And the mechanical structures use the topology design to produce a new still and lightweight part with the different loading.A new structure is created through overlapping these new optimized structure.

Ultra-broadband and wide-angle reflective terahertz polarization conversion metasurface based on topological optimization

Terahertz polarization conversion devices have significant potential applications in various fields such as terahertzimaging and spectroscopy.In this paper,we utilize genetic algorithms to topologically optimize the metasurface unit cellsand design a reflective linear polarization conversion metasurface with ultra-broadband and wide-angle characteristics.By partitioning the metallic pattern layer into quadrants,the encoding length is effectively reduced,resulting in a shorteroptimization time.The research results indicate that the converter possesses a polarization conversion efficiency ratio higherthan 90%and a relative bandwidth ratio of 125%in a range of 0.231-0.995 THz.Meanwhile,it can maintain excellentpolarization conversion properties when the incident angle of terahertz waves is less than 45°and the polarization angle isless than 15°,demonstrating excellent practicality.New insights are provided for the design of terahertz wide-angle ultrawidebandpolarization conversion devices,and the proposed metasurfce has potential applications in terahertz polarizationimaging,spectroscopy and communication fields.