Topology optimization of microstructures of viscoelastic damping materials for a prescribed shear modulus

Damping performance of a passive constrained layer damping (PCLD) structure mainly depends on the geometric layout and physical properties of the viscoelastic damping material. Properties such as the shear modulus of the damping material need to be tailored for improving the damping of the structures. This paper presents a topology optimization method for designing the microstructures in 2D, i.e., the structure of the periodic unit cell (PUC), of cellular viscoelastic materials with a prescribed shear modulus. The effective behavior of viscoelastic materials is derived through the use of a finite element based homogenization method. Only isotropic matrix material was considered and under such assumption it is found that the effective loss factor of viscoelastic material is independent of the geometrical configuration of the PUC. Based upon the idea of a Solid Isotropic Material with Penalization (SIMP) method of topology optimization, the relative material densities of the elements of the PUC are considered as the design variables. The topology optimization problem of viscoelastic cellular material with a prescribed property and with constraints on the isotropy and volume fraction is established. The optimization problem is solved using the sequential linear programming (SLP) method. Several examples of the design optimization of viscoelastic cellular materials are presented to demonstrate the validity of the method. The effectiveness of the design method is illustrated by comparing a solid and an optimized cellular viscoelastic material as applied to a cantilever beam with the passive constrained layer damping treatment.     

Optimal topology design for stress-isolation of soft hyperelastic composite structures under imposed boundary displacements

Soft hyperelastic composite structures that integrate soft hyperelastic material and linear elastic hard material can undergo large deformations while isolating high strain in specified locations to avoid failure. This paper presents an effective topology optimization-based methodology for seeking the optimal united layout of hyperelastic composite structures with prescribed boundary displacements and stress constraints. The optimization problem is modeled based on the power-law interpolation scheme for two candidate materials (one is soft hyperelastic material and the other is linear elastic material). The ?-relaxation technique and the enhanced aggregation method are employed to avoid stress singularity and improve the computational efficiency. Then, the topology optimization problem can be readily solved by a gradient-based mathematical programming algorithm using the adjoint variable sensitivity information. Numerical examples are given to show the importance of considering prescribed boundary displacements in the design of hyperelastic composite structures. Moreover, numerical solutions demonstrate the validity of the present model for the optimal topology design with a stress-isolated region.     

Topology optimization of rubber isolators considering static and dynamic behaviours

A topology optimization for the design of rubber vibration isolators is proposed. Many vibration isolators are made of rubbers and they operate under small oscillatory load superimposed on large static deformation. Vibration isolators must have a certain degree of static stiffness in order to endure the static loading due to large gravitational and inertial forces. On the other hand, isolators must have a small dynamic stiffness in order to reduce the force transmission from vibrating systems to base structures. Therefore both the static and dynamic behaviours of rubber should be simultaneously considered in the design process. The static behaviours of rubber under large and slow loads are generally treated with hyperelastic constitutive models. Rubber under fast dynamic loads can be modelled as a viscoelastic material. In this paper, the steady state viscoelastic model, which is suggested by Kim and Youn and correctly predicts the influence of the pre-strain on the relaxation function, is applied for the dynamic analysis. The continuum-based design sensitivity analyses (DSA) of both the static hyperelastic model and dynamic viscoelastic model are developed. The topology optimization formulation is proposed in order to generate the system layouts considering both the static and dynamic performance. The density distribution approach and sequentially linear programming (SLP) are used as the optimization algorithms. Some design examples are presented in order to verify the proposed approach.     

Microstructural topology optimization of structural-acoustic coupled systems for minimizing sound pressure level

The aim of this paper is to present a microstructural topology optimization methodology for the structural-acoustic coupled system. In the structural-acoustic system, the structure is considered to be a thin composite plate composed of periodic uniform microstructures. The discrete design variables are used in the microstructural topology optimization, and the constitutive matrix is interpolated by the power-law scheme at the micro scale. The equivalent macro material properties of the microstructure are computed through the homogenization method. The design objective is to minimize the sound pressure level (SPL) in an interior acoustic medium. The sensitivities of the SPL with respect to design variables are derived. The bi-directional evolutionary structural optimization (BESO) method is extended to solve the structural-acoustic coupled optimization problem to find the optimal material distribution of the microstructure. Numerical examples of a hexahedral box and an automobile passenger compartment are given to demonstrate the efficiency of the presented microstructural topology optimization method.     

Integrated optimization of the material and structure of composites based on the Heaviside penalization of discrete material model

Based on discrete material optimization and topology optimization technologies, this paper discusses the problem of integrated optimization design of the material and structure of fiber-reinforced composites by considering the characteristics of the discrete variable of fiber ply angle because of the manufacture requirements. An optimization model based on the minimum structural compliance with a specified composite volume constraint is established. The ply angle and the distribution of the composite material are introduced as independent variables in two geometric scales (material and structural scales). The void material is added into the optional discrete material set to realize the topology change of the structure. This paper proposes an improved HPDMO (Heaviside Penalization of Discrete Material Optimization) model to obtain a better convergent result, and an explicit sensitivity analysis is performed. The effects of the HPDMO model on the convergence rate of the optimization results, the objective function value and the iteration history are studied and compared with those from the classical Discrete Material Optimization model and the Continuous Discrete Material Optimization model in this paper. Numerical examples in this paper show that the HPDMO model can effectively achieve the integrated optimization of the fiber ply angle and its distribution in the structural domain, and can also considerably improve the convergence rate of the optimal results compared with other DMO models. This model will help to reduce the manufacture cost of the optimal design.     

Optimal design of periodic functionally graded composites with prescribed properties

The computational design of a composite where the properties of its constituents change gradually within a unit cell can be successfully achieved by means of a material design method that combines topology optimization with homogenization. This is an iterative numerical method, which leads to changes in the composite material unit cell until desired properties (or performance) are obtained. Such method has been applied to several types of materials in the last few years. In this work, the objective is to extend the material design method to obtain functionally graded material architectures, i.e. materials that are graded at the local level (e.g. microstructural level). Consistent with this goal, a continuum distribution of the design variable inside the finite element domain is considered to represent a fully continuous material variation during the design process. Thus the topology optimization naturally leads to a smoothly graded material system. To illustrate the theoretical and numerical approaches, numerical examples are provided. The homogenization method is verified by considering one-dimensional material gradation profiles for which analytical solutions for the effective elastic properties are available. The verification of the homogenization method is extended to two dimensions considering a trigonometric material gradation, and a material variation with discontinuous derivatives. These are also used as benchmark examples to verify the optimization method for functionally graded material cell design. Finally the influence of material gradation on extreme materials is investigated, which includes materials with near-zero shear modulus, and materials with negative Poisson’s ratio.     

A hierarchical genetic algorithm with age structure for multimodal optimal design of hybrid composites

A genetic algorithm aiming the optimal design of composite structures under non-linear behaviour is presented. The approach addresses the optimal material/stacking sequence in laminate construction and material distribution topology in composite structures as a multimodal optimization problem. The proposed evolutionary process is based on a sequential hierarchical relation between subpopulations evolving in separated isolation stages followed by migration. Improvements based on the species conservation paradigm are performed to avoid genetic tendencies due to elitist strategies used in the hierarchical subpopulations. The concept of species is associated with material distribution topology in composite structures, and an enlarged master population with age structure is considered concurrently with the hierarchical topology. Rules based on species concept are imposed on either isolation or migration stages to overcome the predominance of a species and to guarantee the diversity. A mutation process controlled by the stress field is implemented, improving the local genetic search. The proposed model allows multiple solutions for the optimal design problem.     

Design of piezocomposite materials and piezoelectric transducers using topology optimization—Part I

Summary Currently developments of piezocomposite materials and piczoelectric actuators have been based on the use of simple analytical models, test of prototypes, and analysis using the finite element method (FEM), usually limiting the problem to a parametric optimization. By changing the topology of these devices or their components, we may obtain an improvement in their performance characteristics. Based on this idea, this paper discusses the application of topology optimization combined with the homogenization method and FEM for designing piezocomposite materials. The homogenization method allows us to calculate the effective properties of a composite material knowing its unit cell topology. New effective properties that improves the electromechanical efficiency of the piezocomposite material are obtained by designing the piezocomposite unit cell. This method consists of finding the distribution of the material and void phases in a periodic unit cell that optimizes the performance characteristics of the piezocomposite. The optimized solution is obtained using Sequential Linear Programming (SLP). A general homogenization method applied to piczoelectricity was implemented using the finite element method (FEM). This homogenization method has no limitations regarding volume fraction or shape of the composite constituents. The main assumptions are that the unit cell is periodic and that the scale of the composite part is much larger than the microstructure dimensions. Prototypes of the optimized piezocomposites were manufactured and experimental results confirmed the large improvement. Department of Mechanical Engineering and Applied Mechanics Department of Mechanical Engineering and Applied Mechanics     

飞机多目标优化设计网格的研究与应用

针对飞机多目标拓扑优化提出一种通用的遗传算法计算模型,在此模型基础上,基于对等计算(P2P)技术将分布的计算资源整合为高性能计算环境,以网格服务方式提供统一的资源服务和可视化的用户使用环境,实现多目标优化设计网格,解决飞机设计中遇到的复合材料多目标拓扑优化问题.首先对系统体系结构以及多目标遗传算法做出较详细的描述,然后以优化某型大展弦比机翼为例,给出一组实验数据.结果证明,该系统大大缩短了计算时间,具有良好的并行加速效果.     

Multi-objective optimal design of hybrid viscoelastic/composite sandwich beams by using the generalized differential quadrature method and the non-dominated sorting genetic algorithm II

In this study, the multi-objective optimal design of hybrid viscoelastic/composite sandwich beams for minimum weight and minimum vibration response is aimed. The equation of motion for linear vibrations of a multi-layer beam is derived by using the principle of virtual work in the most general form. These governing equations together with the boundary conditions are discretized by the generalized differential quadrature method (GDQM) in the frequency domain for the first time. Also, the time and temperature dependent properties of the viscoelastic materials are taken into consideration by a novel ten-parameter fractional derivative model that can realistically capture the response of these materials. The material variability is accounted for by letting an optimization algorithm choose a material freely out of four fiber-reinforced composite materials and five viscoelastic damping polymers for each layer. The design parameters, i.e., the orientation angles of the composites, layer thicknesses and the layer materials that give the set of optimal solutions, namely the Pareto frontier, is obtained for the three and nine-layered clamped-free sandwich beams by using a variant of the non-dominated sorting genetic algorithms (NSGA II).     

Discrete material selection and structural topology optimization of composite frames for maximum fundamental frequency with manufacturing constraints

Structural and Multidisciplinary Optimization - This paper proposes a methodology for simultaneous optimization of composite frame topology and its material design considering specific...     

Multi-material structural topology optimization with decision making of stiffness design criteria

A new methodology for making design decisions of structures using multi-material optimum topology information is presented. Multi-material analysis contributes significant applications to enhance the bearing capacity and performance of structures. A method that chooses an appropriate material combination satisfying design stiffness requirement economically is currently needed. An alternative method of making design-decision is to utilize a multi-material topology optimization (MMTO) approach. This study provides a new computational design optimization procedure as a guideline to find the optimal multi-material design by considering structure strain energy and material cost. The MMTO problem is analyzed using an alternative active-phase approach. The procedure consists of three design steps. First, steel grid configurations and composite with material properties are defined as a given structure for automatic design decision-making (DDM). And then design criteria of the steel composites structure is given to be limited strain energy by designers and engineers. Second, topology changes in the automatic distribution of multi-steel materials combination and volume control of each material during optimization procedures are achieved and at the same time, their converged minimal strain energy is produced for each material combination. And third, the strain energy and material cost which is computed based on the material ratio in the combinations are used as design decision parameters. A study in constructional steel composites to produce optimal and economical multi-material designs demonstrates the efficiency of the present DDM methodology.     

Development of a structural optimization strategy for the design of next generation large thermoplastic wind turbine blades

This paper presents the development of a structural optimization process for the design of future large thermoplastic wind turbine blades. The optimization process proposed in this paper consists of three optimization steps. The first step is a topology optimization of a short untwisted and non tapered section of the blade, with the inner volume used as the design domain. The second step is again a topology optimization, but on the first half of a blade to study the effect of non symmetry of the structure due to blade twist and taper. Results of this optimization step are then interpreted to build a shell model of the complete blade structure to perform composite size optimization based on a minimum mass objective subjected to constraints on deflection, composite strength and structural stability. Different blade models using ribs are then optimized and compared against conventional blade structure (box spar structure without ribs and single web structure without ribs). The use of ribs in wind turbine blade structures, which is more adapted to thermoplastic composite manufacturing than for thermoset composites, leads to slightly lighter blades than conventional blade structures.     

Multi-material topology optimization with multiple volume constraints: a general approach applied to ground structures with material nonlinearity

Multi-material topology optimization is a practical tool that allows for improved structural designs. However, most studies are presented in the context of continuum topology optimization – few studies focus on truss topology optimization. Moreover, most work in this field has been restricted to linear material behavior with limited volume constraint settings for multiple materials. To address these issues, we propose an efficient multi-material topology optimization formulation considering material nonlinearity. The proposed formulation handles an arbitrary number of candidate materials with flexible material properties, features freely specified material layers, and includes a generalized volume constraint setting. To efficiently handle such arbitrary volume constraints, we derive a design update scheme that performs robust updates of the design variables associated with each volume constraint independently. The derivation is based on the separable feature of the dual problem of the convex approximated primal subproblem with respect to the Lagrange multipliers, and thus the update of design variables in each volume constraint only depends on the corresponding Lagrange multiplier. Through examples in 2D and 3D, using combinations of Ogden-based, bilinear, and linear materials, we demonstrate that the proposed multi-material topology optimization framework with the presented update scheme leads to a design tool that not only finds the optimal topology but also selects the proper type and amount of material. The design update scheme is named ZPR (phonetically, zipper), after the initials of the authors’ last names (Zhang-Paulino-Ramos Jr.).     

Simultaneous shape and topology optimization of shell structures

In this research, Method of Moving Asymptotes (MMA) is utilized for simultaneous shape and topology optimization of shell structures. It is shown that this approach is well matched with the large number of topology and shape design variables. The currently practiced technology for optimization is to find the topology first and then to refine the shape of structure. In this paper, the design parameters of shape and topology are optimized simultaneously in one go. In order to model and control the shape of free form shells, the NURBS (Non Uniform Rational B-Spline) technology is used. The optimization problem is considered as the minimization of mean compliance with the total material volume as active constraint and taking the shape and topology parameters as design variables. The material model employed for topology optimization is assumed to be the Solid Isotropic Material with Penalization (SIMP). Since the MMA optimization method requires derivatives of the objective function and the volume constraint with respect to the design variables, a sensitivity analysis is performed. Also, for alleviation of the instabilities such as mesh dependency and checkerboarding the convolution noise cleaning technique is employed. Finally, few examples taken from literature are presented to demonstrate the performance of the method and to study the effect of the proposed concurrent approach on the optimal design in comparison to the sequential topology and shape optimization methods.     

Parallelized structural topology optimization and CFD coupling for design of aircraft wing structures

A set of structural optimization tools are presented for topology optimization of aircraft wing structures coupled with Computational Fluid Dynamics (CFD) analyses. The topology optimization tool used for design is the material distribution technique. Because reducing the weight requires numerous calculations, the CFD and structural optimization codes are parallelized and coupled via a code/mesh coupling scheme. In this study, the algorithms used and the results obtained are presented for topology design of a wing cross-section under a given critical aerodynamic loading and two different spar positions to determine the optimum rib topology.     

On simultaneous shape and material layout optimization of shell structures

This work presents a computational method for integrated shape and topology optimization of shell structures. Most research in the last decades considered both optimization techniques separately, seeking an initial optimal topology and refining the shape of the solution later. The method implemented in this work uses a combined approach, were the shape of the shell structure and material distribution are optimized simultaneously. This formulation involves a variable ground structure for topology optimization, since the shape of the shell mid-plane is modified in the course of the process. It was considered a simple type of design problem, where the optimization goal is to minimize the compliance with respect to the variables that control the shape, material fraction and orientation, subjected to a constraint on the total volume of material. The topology design problem has been formulated introducing a second rank layered microestructure, where material properties are computed by a “smear-out” procedure. The method has been implemented into a general optimization software called ODESSY, developed at the Institute of Mechanical Engineering in Aalborg. The computational model was tested in several numerical applications to illustrate and validate the approach.     

Knowledge discovery in databases for determining formulation in topology optimization

Whereas topology optimization has achieved immense success, it involves an intrinsic difficulty. That is, optimized structures obtained by topology optimization strongly depend on the settings of the objective and constraint functions, i.e., the formulation. Nevertheless, the appropriate formulation is not usually obvious when considering structural design problems. Although trial-and-error to determine appropriate formulations are implicitly performed in several studies on topology optimization, it is important to explicitly support the process of trial-and-error. Therefore, in this study, we propose a new framework for topology optimization to determine appropriate formulations. The basic idea of this framework is incorporating knowledge discovery in databases (KDD) and topology optimization. Thus, we construct a database by collecting various and numerous material distributions that are obtained by solving various structural design problems with topology optimization, and find useful knowledge with respect to appropriate formulations from the database on the basis of KDD. An issue must be resolved when realizing the above idea, namely the material distribution in the design domain of a data record must be converted to conform to the design domain of the target design problem wherein an appropriate formulation should be determined. For this purpose, we also propose a material distribution-converting method termed as design domain mapping (DDM). Several numerical examples are used to demonstrate that the proposed framework including DDM successfully and explicitly supports the process of trial-and-error to determine the appropriate formulation.