TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization...

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TOPOLOGY OPTIMIZATION: FUNDAMENTALS Pierre DUYSINX LTAS – Automotive Engineering Academic year 2019-2020 1

Transcript of TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization...

Page 1: TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or

TOPOLOGY OPTIMIZATION: FUNDAMENTALS

Pierre DUYSINX

LTAS – Automotive Engineering

Academic year 2019-2020

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LAY-OUT

Introduction

Topology problem formulation– Problem statement

Compliance minimization

Homogenization method vs SIMP based

Sensitivity analysis

Optimality criteria

Filtering techniques

Conclusion

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INTRODUCTION

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What is topology?

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STRUCTURAL & MULTIDISCIPLINARY OPTIMISATION

TYPES OF VARIABLES

– a/ Sizing

– b/ Shape

– c/ Topology

– (d/ Material)

TYPES OF OPTIMISATION

– structural

– multidisciplinary

structural

aerodynamics,

thermal,

manufacturing

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Topology optimization

One generally distinguishes two approaches of topology optimization:

– Topology optimization of naturally discrete structures (e.g. trusses)

– Topology optimization of continuum structures (eventually after FE discretization)

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Why topology optimization?

CAD approach does not allow topology modifications

A better morphology by topology optimization

[Duysinx, 1996]

[Zhang et al. 1993]

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TOPOLOGY PROBLEM FORMULATION

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TOPOLOGY OPTIMIZATION FORMULATION

Abandon CAD model description based on boundary description

Optimal topology is given by an optimal material distribution problem

Search for the indicator function of the domain occupied by the material

The physical properties write

The problem is intrinsically a binary 0-1 problem ➔ solution is extremely

difficult to solve9

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MATERIAL DENSITY FUNCTION

Avoid 0/1 problem and replace by a continuous approximation considering a variable density material running from void (0) to solid (1)

– Homogenization law of mechanical properties of a porous material for any volume fraction (density) of materials

– Mathematical interpolation and regularization

SIMP model RAMP

Penalization of intermediate densities to end-up with black and white solutions

Efficient solution of optimization problem based on sensitivity analysis and gradient based mathematical programming algorithms

0* EE p=

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TOPOLOGY OPTIMIZATION: FORMULATION

Well-posed ness of problem? Discretised problem is ill-posed

– Mesh-dependent solutions

– Recreate microstructures

– Nonexistence and uniqueness of a solution

Homogenisation Method:

→ Extend the design space to all

porous composites of variable density

Filter method / Perimeter method /

Slope constraints:

→ Restrict the design space by

eliminating chattering designs from the design space

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HOMOGENIZATION METHOD

Select one family of microstructures whose geometry is fully parameterized in terms of a set of design variables [Bendsoe and Kikuchi, 1988]

– G closure : optimal microstructure (full relaxation)

– Suboptimal microstructures (partial relaxation)

Use homogenization theory to compute effectives properties: in terms of microstructural geometrical parameters: Eijk = Eh

ijkl(a,b,…)

Difficult to interpret and fabricate the optimal material distribution as it is

Revival interest with arrival of cellular structures e.g. lattice structures made by additive manufacturing

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POWER LAW MODEL (SIMP)

Simplified model of a microstructured material with a penalisation of intermediate densities [Bendsoe, 1989]

Stiffness properties:

Strength properties:

Alternative schemes: RAMP

Can be related to actual micro geometries [Bendsoe and Sigmund, 1999]

90% of current topology optimization runs

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IMPLEMENTION OF MATERIAL DENSITY FUNCTION

Implementation of material density approach is rather easy:

– Fixed mesh

– Design variables are element or nodal densities

– Similar to sizing problem

– SIMP law is easy to code

– Sensitivity of compliance is

cheap

– Use efficient gradient based

optimization algorithms as

MMA

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A FIRST EXAMPLE: GENESIS OF A STRUCTURE

15[E. Lemaire, PhD Thesis, Uliege, 2013]

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TOPOLOGY OPTIMIZATION AS A

COMPLIANCE MINIMIZATION PROBLEM

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DESIGN PROBLEM FORMULATION

The fundamental problem of topology optimization deals with the optimal material distribution within a continuum structure subject to a single static loading.

In addition one can assume that

the structure is subject to homogeneous

boundary conditions on Gu.

The principle of virtual work writes

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DESIGN PROBLEM FORMULATION

A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or alternatively the mass of the structure,

while achieving a given level of functional (mechanical) performance.

Following Kohn (1988), the problem is well posed from a mathematical point of view if the mechanical behaviour is sufficiently smooth. Typically one can consider :

– Compliance (energy norm)

– A certain norm of the displacement over the domain

– A limitation of the maximum stress18

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DESIGN PROBLEM FORMULATION

Compliance performance: The mechanical work of the external loads

– Using finite element formulation

Limitation of a given local stress measure ||s(x)|| over a sub-domain W2 excluding some neighborhood of singular points related to some geometrical properties of the domain (reentrant corners) or some applied point loads

Stress measure ||s(x)|| → Von Mises, Tresca, Tsai-Hill…19

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DESIGN PROBLEM FORMULATION

The average displacement (according to a selected norm) over the domain or a subdomain W1 excluding some irregular points

If one considers the quadratic norm and if the finite element discretization is used, one reads

Assuming a lumped approximation of the matrix M, one can find the simplified equivalent quadratic norm of the displacement vector

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DESIGN PROBLEM FORMULATION

The choice of the compliance is generally the main choice made by designers.

– At equilibrium, the compliance is also the strain energy of the structure, so that compliance is the energy norm of the displacements giving rise to a smooth displacement field over the optimized structure.

– One can interpret the compliance as the displacement under the loads. For a single local case, it is the displacement under the load.

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DESIGN PROBLEM FORMULATION

The choice of the compliance is generally the main choice of designers.

– The sensitivity of compliance is easy to calculate. Being self adjoined, compliance is self adjoined, and it does not require the solution of any additional load case.

– Conversely local stress constraints call for an important amount of additional CPU to compute the local sensitivities.

– One can find analytical results providing the optimal bounds of composites mixture of materials for a given external strain field. The problem is known as the G-closure

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DESIGN PROBLEM FORMULATION

Finally the statement of the basic topology problem writes:

Alternatively it is equivalent for particular bounds on the volume and the compliance to solve the minimum compliance subject to volume constraint

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DESIGN PROBLEM FORMULATION

Minimize compliance

s.t.

– Given volume

– (bounded perimeter)

– (other constraints)

Maximize eigenfrequencies

s.r.

– Given volume

– (bounded perimeter)

– (other constraints)

Minimize the maximum of the local failure criteria

s.t.

– Given volume

– (bounded perimeter)

– (other constraints)

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PROBLEM FORMULATION

Maximum strength problem:

Where is a strength criterion predicting the end of the elastic linear regime in the material and in the microstructure

Investigation of overstressing in the microstructure due to micro porosities based on rank-2 materials leads to the conclusion that

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PROBLEM FORMULATION

For several load cases, average compliance

Or better a worst-case approach

– Where k is load case index, K is the stiffness matrix of FE approximated problem, gk, and qk are the load case and generalized displacement vectors for load case k

– and (x) is the local density and V is the volume 26

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MULTIPLE LOAD CASE FORMULATION

Min-max formulation

Is equivalent to

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MULTIPLE LOAD CASE

Importance of treating separately the different load case!

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Traction alone Shear alone Traction + Shear

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MULTIPLE LOAD CASE

Importance of treating separately the different load case!

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Load case 1

Load case 2

x

y

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MULTIPLE LOAD CASE

Importance of treating separately the different load case!

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Load case 1 only Load case 2 only Load case 1 and 2

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MULTIPLE LOAD CASE

Importance of treating separately the different load case!

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Load case 1+2 Load case 1-2 Max Load case 1 and 2

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TOPOLOGY OPTIMIZATION USING HOMOGENIZATION

VSSIMP BASED TOPOLOGY

OPTIMIZATION

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TOPOLOGY OPTIMIZATION

Optimal material distributions are not easy problems:

– Mesh dependency of numerical solutions

– Natural tendency to generate microstructures and composite solutions

– Mathematical difficulties: non existence and uniqueness of a solution

Page 34: TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or

TOPOLOGY OPTIMIZATION

Two solutions:

1/ Homogenisation Method:

Extend the design space to all porous composites of variable density

2/ Perimeter method:

Filter method:

Restrict solution design space and eliminate chattering designs from design space

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TOPOLOGY OPTIMIZATION

Homogenisation Method:

– Introduce a family of composites of variable density

– Geometry is fully parameterized in terms of a set of design variables

– Use homogenization theory to compute numerically or analytically their effective properties

– Design variables are the local geometrical parameter of the microstructural design: a, b, q

– Optimization problem is similar to a large scale sizing problem

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HOMOGENIZATION METHOD

Extend the design space to all porous composites of variable density

In practice: Select one family of microstructures

– G closure : optimal microstructure (full relaxation)

– Suboptimal microstructures (partial relaxation)

Rank 2 materials

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HOMOGENISATION METHOD

Each point (E.F.) is made of a porous microstructure whose geometric parameters become the design variables

Introduction of optimal or sub-optimal microstructures

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Layered materials

Parametric micro geometries

Page 38: TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or

HOMOGENIZATION METHOD

Investigation of the influence of the selected microstructure upon the optimal topology :

– 1° orthotropic v.s. isotropy

– 2° penalization of intermediate properties38

From anisotropic to isotropic materials

Penalization of intermediate densities

Page 39: TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or

POWER LAW MODEL (SIMP)

Simplified model of a microstructured material (SIMP) with a penalisation of intermediate densities

Stiffness properties:

Modified SIMP should be preferred to avoid singularities

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ALTERNATIVE PARAMETRIZATION TO SIMP

Alternatively RAMP

parameterization [Stolpe &

Svanberg, 2001] enables controlling the slope at zero density

Halpin Tsai (1969)

Polynomial penalization

[Zhu, 2009]:

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SIMP : PENALIZATION OF INTERMEDIATE DENSITIES

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SIMP with p=2 SIMP with p=3

SIMP with p=4

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POWER LAW MODEL (SIMP)

Prescribing immediately a high penalization may introduce some numerical difficulties:

– Optimization problem becomes difficult to solve because of the sharp variation of material properties close to x=1

– Optimization problem includes a lot of local optima and solution procedure may be trapped in one of these.

To mitigate these problems, one resorts to the so-called continuation procedure in which p is gradually increased from a small initial value till the desired high penalization.

Typically:

– p(0) = 1.6

– p(k+1) := p(k) + Dp after a given number of iterations

or when a convergence criteria is OK42

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FILTERING TECHNIQUESAND

MESH INDEPENDENCY STRATEGIES

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Two numerical difficulties

Checkerboard patterns: numerical instabilities related to the inconsistency between the displacement and density fields.

– Appearance of alternate black-white patterns

– Checkerboard patterns replaces intermediate densities

Mesh dependency: the solution depends on the computing mesh.

– New members appears when refining the mesh

– Number of holes and structural features are modified when changing the mesh.

– Stability (and meaning) of solutions? 44

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Checkerboard patterns

Numerically inconsistent discretization scheme of density and displacement fields ➔ checkerboard patterns are artificially stiff

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Checkerboard patterns

Babuska Brezzi conditions of discretization schemes

Checkerboard free numerical schemes

– High order FE elements

– Filtering density field solutions ➔ lower order

density fields

– Perimeter constraint

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Checkerboard patterns

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FE u: degree 2 / Density : constant

Solution with checkerboardsSIMP with p=2FE u: degree 1 / Density : constant

With perimeter constraint

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Checkerboard patterns

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FE u: degree 2

SIMP with p=3. FE u: degree 1

Perimeter < 60

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Checkerboard patterns

49FE u: degree 2

SIMP with p=3. FE u: degree 1

Perimeter < 60

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Mesh dependency

Mesh independent solution: insure mesh independent filtering of lower size details

– Low pass filter [Sigmund (1998)]

– Perimeter constraint [Ambrosio & Butazzo (1993)]

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Mesh independency

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Perimeter < 60

FE u: degree 1

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PERIMETER METHOD

Ambrosio and Buttazzo, (1993): Adding a perimeter constraint to optimal material problem regularizes the design problem

Haber, Jog, and Bendsoe (1996): Perimeter method in topology optimization

Efficient numerical solution: Duysinx (1996), Beckers (1997)

Extension from 2D problems to 3D and axi-symmetric geometries

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Page 53: TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or

PERIMETER METHOD

Eliminate chattering designs with a bounded perimeter

Restriction of the design space

Similar to the filter method (Sigmund)

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Page 54: TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or

PERIMETER METHOD

Continuous version of perimeter measure

– With the gradient of the density field and the jump []j of the density across discontinuity surfaces j

The continuous approximation of the modulus of the gradient

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PERIMETER METHOD

The complexity of the structure is controlled with a bound over the perimeter

An efficient numerical strategy has been elaborated to cater with the difficult perimeter constraint

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FILTERING MATERIAL DENSITIES

To avoid mesh dependency and numerical instabilities like checkerboards patterns, one approach consists in restricting the design space of solutions by forbidding high frequency variations of the density field.

Basic filtering by Bruns and Tortorelli (2001), proven by Bourdin (2001)

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FILTERING MATERIAL DENSITIES

Other weighting functions

– Gaussian

– Constant

Density filter is equivalent to solving a Helmotz equation Lazarov et al.

With the following Neuman boundary conditions

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FILTERING MATERIAL DENSITIES

Historically Ole Sigmund (1994, 1997) introduced a filter of the sensitivities

with

For non uniform meshes, Sigmund proposed to use

The smoothed sensitivities correspond to the sensitivities of a smoothed version of the objective function (as well as the constraints) 58

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FILTERING MATERIAL DENSITIES

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FILTERING MATERIAL DENSITIES

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FILTERING MATERIAL DENSITIES

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• Mesh dependent• Checkerboard• Non-Discrete

Solut.

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HEAVISIDE FILTER

To obtain 0/1 solutions , Guest et al. (2014) modifies the density filter with a Heaviside function such that if xe>0, the Heaviside gives a physical value of the density equal to ‘1’ and if the xe=0, the Heaviside gives a density ‘0’

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Page 63: TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or

HEAVISIDE FILTER

To obtain 0/1 solutions , Guest et al. (2014) modifies the density filter with a Heaviside function such that if xe>0, the Heaviside gives a physical value of the density equal to ‘1’ and if the xe=0, the Heaviside gives a density ‘0’

Heaviside smooth approximation

– For b→ 0, the filter gives the original filter

– For b→ infinity, the function reproduces the max operator,

that is the density becomes 1 if there is any element in the neighborhood that is nonzero.

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HEAVISIDE FILTER

Heaviside smooth approximation

– For b→ 0, the filter gives the original filter

– For b→ infinity, the function reproduces the max operator,

that is the density becomes 1 if there is any element in the neighborhood that is non zero. 64

Page 65: TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or

HEAVISIDE FILTER

To obtain 0/1 solutions , Guest et al. (2014) modifies the density filter with a Heaviside function such that if xe>0, the Heaviside gives a physical value of the density equal to ‘1’ and if the xe=0, the Heaviside gives a density ‘0’

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• Mesh dependent• Checkerboard• Non-Discrete Solution• Need of continuation / Large number of iterations (>100)

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HEAVISIDE FILTER

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• Mesh dependent• Checkerboard• Non-Discrete Solution• Need of continuation / Large number of iterations (>100)• Does not ensure minimum length scale in some problems

(Thermal, Displacement).• Length scale control of one phase only.

F u

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HEAVISIDE FILTER

Heaviside function can be extended (Wang, Lazarov, Sigmund, 2011) to control minimum and maximum length scale

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HEAVISIDE FILTER

Heaviside function enables a control of manufacturing tolerant designs ➔ robust design

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F u

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THE THREE FIELD APPROACH

Combining density filtering and Heaviside filter give rise to the so called three field topology optimization scheme proposed by Wang et al. (2011), one uses a design field, a filtered field and a physical field whose relations are defined though the following filter and thresholding processes

– Filtering

– Heaviside

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SENSITIVITY ANALYSIS

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SENSITIVITY ANALYSIS

Study of the derivatives of the structure under linear static analysis when discretized by finite elements.

The study is carried out for one load case, but it can be easily extended to multiple load cases.

Equilibrium equation of the discretized structure:

– q generalized displacement of the structure

– K stiffness matrix of the structure discretized into F.E.

– g generalized load vector consistent with the F.E. discretization

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SENSITIVITY ANALYSIS

Let x be the vector of design variables in number n.

The differentiation of the equilibrium equation yields the sensitivity of the generalized displacements:

The right hand side term is called pseudo load vector

Physical interpretation of the pseudo load (Irons): load that is necessary to re-establish the equilibrium when perturbating the design. 72

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SENSITIVITY ANALYSIS

A central issue is the calculation of the derivatives of the stiffness matrix and of the load vector.

In some cases the structure of the stiffness matrix makes it easy to have the sensitivity of the matrix with respect to the design variable

In topology optimization using SIMP model:

The stiffness matrix

And its derivatives

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SENSITIVITY OF COMPLIANCE

The compliance is defined as the work of the applied load.

It is equal to the twice the deformation energy

The derivative of the compliance constraint gives:

Introducing the value of the derivatives of the generalized displacements:

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SENSITIVITY OF COMPLIANCE

The expression of the sensitivity of the compliance writes

Generally the load vector derivative is zero (case of no body load), it comes:

In fact, we could have obtained this result also by using the virtual load approach:

75

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SOLVING TOPOLOGY OPTIMIZATION PROBLEM

USING OPTIMALITY CRITERIA

76

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OPTIMALITY CRITERIA

One considers the fundamental problem of compliance minimization subject to a volume constraint

Compliance is an implicit, non linear function of the density variables. To do so one can either

– Use the virtual work principle

– Make a first order Taylor expansion with respect to the inverse (reciprocal) variables.

77

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OPTIMALITY CRITERIA

Compliance is the strain energy at equilibrium

Decompose into FE element contributions

Stiffness matrix dependency on density variables

And

78

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OPTIMALITY CRITERIA

For isostatic structures, for which the load vector remains constant, we have also that the element displacement vector of an inverse function of the design variable:

Therefore the following quantity remain constant for isostatic structures.

For hyperstatic structures, it does not remain constant but it is reasonable to assume that generally it does change too much from one iteration to another

79

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OPTIMALITY CRITERIA

Therefore one can define:

ci is constant for a statically determinate structure. We get an explicit expression which is a good approximation of the compliance in the neighborhood of the current design point:

80

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OPTIMALITY CRITERIA

It can be noticed from now that the same expression can be obtained if we perform a first order Taylor expansion of the compliance with respect to the intermediate variables

The Taylor expansion of the compliance writes

81

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OPTIMALITY CRITERIA

One can demonstrate that

Let’s define the coefficient

so that we get exactly the same explicit expression of the compliance

82

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OPTIMALITY CRITERIA

We can demonstrate that this last expression is exactly the same as the first one because, the coefficients ci are exactly the same ones as we defined previously using the engineering approach based on the decomposition of the strain energy

We have

83

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OPTIMALITY CRITERIA

The fundamental compliance minimization problem

Using approximation concepts, we get an explicit (sub)-problem that can be solved more efficiently may be at the price of repeating iteratively the process of generating the subproblems:

84

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OPTIMALITY CRITERIA

Let introduce the Lagrange multiplier l and let's shape the Lagrange function

Stationary conditions (from KKT conditions)

It gives

85

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OPTIMALITY CRITERIA

The stationarity conditions gives:

If ci>0, the xi variable is called as active.

If ci<0, the Langrangian function is monotonic increasing, so that the minimum is

The variable is said passive.

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OPTIMALITY CRITERIA

To identify the Lagrange variable, one substitutes the xi(l) by its value into the volume constraint that is satisfied as an equality constraint:

It comes

And

with

87

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OPTIMALITY CRITERIA

We have

It can be solved analytically or numerically

Finally the optimized value is reused into the primal variables

88

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OPTIMALITY CRITERIA

For statically determinate case, the ci remain constant and one structural analysis and reach the optimum. For statically indeterminate case ci is not constant, one has to use an iterative scheme.

And the iteration scheme

89

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OPTIMALITY CRITERIA

If we remember that

It follows

The quantity has the meaning of strain energy unit volume

90

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OPTIMALITY CRITERIA

For active variables (i.e. ci>0),

For passive variables (i.e. ci<0),

This reminds the iteration scheme proposed by Bendsoe and Kikuchi (1988)

91

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NUMERICAL SOLUTION OF TOPOLOGY PROBLEMS

USING GRADIENT BASED MATH PROGRAMMING

92

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NUMERICAL SOLUTION OF TOPOLOGY OPTIMIZATION PROBLEMS

Optimal material distribution = very large-scale problem

– Large number of design variables: 1 000 → 100 000

– Number of restrictions:

1 → 10 (for stiffness problems)

1 000 → 10 000 (for strength problem with local constraints)

Solution approach based on the sequential programming approach and mathematical programming

– Sequence of convex separable problems based on structural approximations

– Efficient solution of sub problems based on dual maximization

Major reduction of solution time of optimization problem

Generalization of problems that can be solved

93

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SEQUENTIAL CONVEX PROGRAMMING APPROACH

Direct solution of the original

optimisation problem which is

generally non-linear, implicit

in the design variables

is replaced by a sequence of optimisation sub-problems

by using approximations of the responses and using powerful

mathematical programming algorithms94

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SEQUENTIAL CONVEX PROGRAMMING APPROACH

Two basic concepts:

– Structural approximations replace the implicit problem by an

explicit optimisation sub-problem using convex, separable,

conservative approximations; e.g. CONLIN, MMA

– Solution of the convex sub-problems: efficient solution using dual

methods algorithms or SQP method.

Advantages of SCP:

– Optimised design reached in a reduced number of iterations: 10 to

20 F.E. analyses

– Efficiency, robustness, generality, and flexibility, small computation

time

– Large scale problems in terms of number of design constraints and

variables 95

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Linear approximation and Sequential Linear Programming

Linear approximation = first order Taylor expansion around x0:

When linear approximation is applied to each function of the problem, one transforms the problem into a sequence of linear programming problems (SLP):

96

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SEQUENTIAL LINEAR PROGRAMMING METHOD

The current design point is x(k). Using the first order Taylor expansion of f(x), hj(x), we can get a linear approximation of the NL problem in x(k):

Solving this LP problem, we get a new point in x(k+1) and start again.

97

DOESN’T WORK!

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SEQUENTIAL LINEAR PROGRAMMING METHOD

MOVE LIMIT STRATEGY

Introduce a box constraint around the current design point to limit the variation domain of the design variables

Of course take the most restrictive constraints with the side constraints

98

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STRUCTURAL APPROXIMATIONS

Convex Linearisation (CONLIN)

Method of Moving Asymptotes (MMA)

99

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CONLIN approximation

45 90 180

100

105

110

115

120

125

130

135

140

145Strain Energy

(N/mm)

krX k

lX

)(Xg

)(~ Xgr

)(~ Xgl

Approximation of the strain energy in a two plies symmetric laminate subject to shear load and torsion (Bruyneel and Fleury, 2000)

100

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MMA approximation

Approximation of the strain energy in a two plies symmetric laminate subject to shear load and torsion (Bruyneel and Fleury, 2000)

45 90 135 180

100

105

110

115

120

125

130

135

140

145

kX

Strain Energy(N/mm)

kL

)(Xg

)(~ Xg

*kX 45 90 180

100

105

110

115

120

125

130

135

140

145

kX

kU

Strain Energy

(N/mm)

)(Xg

)(~ Xg

*kX

101

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DUAL METHODS

Primal problem

Lagrange function

If the problem is convex…

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DUAL METHODS

Dual problem

– with

Solve Lagrangian problem

Lagrangian problem

103

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NUMERICAL APPLICATIONSOF COMPLIANCE

MINIMIZATION BASED TOPOLOGY OPTIMIZATION

104

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x

y-1000N

-150N

1000N

150N

-5000N

-7500N

Optimization of a maximum stiffness bicycle frame

Load cases

Optimum topology

Non conventional design

Conventional design

105

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Design of a Crash Barrier Pillar (SOLLAC)

106

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3D cantilever beam problem

No perimeter constraint

E=100 N/m², n=0.3

20 x 32 x 4 = 2560 F.E.s

107

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An industrial application: Airbus engine pylon

Application – carried out by SAMTECH and

ordered by AIRBUS

Engine pylon= structure fixing engines to the

wing

Initial Model– CATIA V5 import → Samcef

Model

– BC’s: through shell and beam FE

– 10 load cases: GUSTS

FBO (Fan blade out)

WUL (Without undercarriage landing)

108

Over 250.000 tetraedral FE

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An industrial application: Airbus engine pylon

Target mass: 10%

Additional constraints:– Engine CoG position

Optimization parameters

– Sensitivity filtering: (Sigmund’s filter)

– Symmetry (left right) condition

– Penalty factor

CONLIN optimizer: special version for topology optimization 109

Sensitivities filtering

Penalty factor from 2 to 4

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Airbus engine pylon

110With courtesy by Samtech and Airbus Industries

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Airbus engine pylon

111With courtesy by Samtech and Airbus Industries

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Sandwich panel optimization

Geometry of the sandwich panel reinforcement problem

Optimal topology

112

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Sandwich panel optimization

Geometry of the sandwich panel reinforcement problem

Optimal topology

113

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PLATE AND SANDWICH PLATE MODELS

(a) (b)

(c) (d)

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USING SIMP MODEL FOR TOPOLOGY OPTIMISATION OF PLATES AND SHELLS

0.0 0.25 0.5 0.75 1.0

is replaced by:

PHYSICAL MEANING OF DENSITY VARIABLE:

Page 116: TOPOLOGY OPTIMIZATION: FUNDAMENTALS · DESIGN PROBLEM FORMULATION A typical topology optimization problem is to find the best subset of the design domain minimizing the volume or

PROTOTYPE CAR BODY OPTIMIZATION

Load case 1: bending

– Self weight

– Components (20 kg)

– Pilot (50 kg)

– Roll-over load (70 kg on top of roll cage)

Load case 2: torsion + bending = curb impact

– Rear axle clamped

– Right front wheel free supported

– Left front wheel withstanding 3 times the weight of the axle

70 kg

weight x 3= 2700 N(Figures from Happian-Smith)

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DESIGN OF A URBAN CONCEPT STRUCTURE

Topology optimization of the truss structure

– Target mass of 15 kg

– Minimum compliance

– Mostly determined by load case 2 (torsion)

– SIMP material with p=3

– Left / right symmetry of material distribution

– Filtering

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DESIGN OF A URBAN CONCEPT STRUCTURE

Convergence history118

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DESIGN OF A URBAN CONCEPT STRUCTURE

Volume = 40%

Volume = 20%

Volume = 60%119

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DESIGN OF A URBAN CONCEPT STRUCTURE

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Acknowledgments

This work was partly supported by the

Walloon Region of Belgium and MECATECH

(Mechanical Engineering Pole of

Competitiveness of Wallonia), through the

project MT FAB+

121