Engineering Optimization

Concepts and Applications

F
WB 1440

?
Fred van Keulen
Matthijs Langelaar
CLA H21.1
[email protected]
Engineering Optimization – Concepts and Applications
 Contents
● Sensitivity analysis:

– Brief recap discrete / SA approach

– Adjoint method

– Continuum sensitivities

● Topology optimization

● Closure

Engineering Optimization – Concepts and Applications

 Structural optimization
t
E, 

L
R
h
r

Engineering Optimization – Concepts and Applications

 Topology optimization
● Topology:  (place),  (study):
~ the way parts of an object are connected
to each other
● More general than
shape optimization!
No a priori ? F
assumptions
needed about shape

Engineering Optimization – Concepts and Applications

 Heuristic Methods
● Hard-kill

● Soft-kill

● Etc. etc.

Engineering Optimization – Concepts and Applications

 Milestones
● Michell, 1904: “Michell
truss”
Structures with optimal
stiffness for a given weight
● Bendsoe & Kikuchi, 1988:
Homogenization method

Suzuki & Kikuchi (1991)

Engineering Optimization – Concepts and Applications

 “Classical” Approaches
Ai

● Various approaches:

– Ground structure
approach
(truss sizing)
– Sheet thickness
optimization
(thickness sizing) ti

– Homogenization approach
(microstructure sizing)
hi, bi
Engineering Optimization – Concepts and Applications
 Compliance minimization
● Classical problem: for a given amount
of material, find the stiffest structure
– Save material costs (bridge, building)

– Improve dynamic performance (automotive, machines)

– Save fuel costs (aerospace)

● Stiffest structure = structure with minimal compliance:

Linear elasticity: Ku  f
Compliance: C  f T u  uT Ku
Engineering Optimization – Concepts and Applications
 Compliance minimization (2)
● Optimal solution has infinitely fine
porous microstructure: impractical
● Remedy 1: restrict solution to pure solid/void designs
+ Manufacturable
- Mesh refinement leads to more detailed solutions

● Remedy 2: restrict minimal member sizes

Engineering Optimization – Concepts and Applications

 Compliance minimization (3)
● Conventional approach:

– Assign density variables to every element

i
p
– Young’s modulus depends on density: Ei   i E0
SIMP (Solid Isotropic Material with Penalization)
– Solve optimization problem: min f T u
ρ

s . t . K (ρ)u  f
V i i  mmax
0   min   i  1

Engineering Optimization – Concepts and Applications

 SIMP
● SIMP approach uses penalization to make intermediate
p
densities unattractive: Ei   i E0
– Lower stiffness/weight ratio

– Forces design to solid/void solution

E
E0 p 1
p = 1; C = 184 p = 1.5; C = 210
p2

p3

 p = 2; C = 220 p = 3; C = 229

Engineering Optimization – Concepts and Applications

 Mesh independence /
checkerboard filtering
● Problems:

– Checkered solid/void patterns have

artificially high stiffness (unrealistic)
– Solution dependent on mesh size

● Heuristic solution: spatial filtering

– Filtering of sensitivities or density

values
– Filter radius determines minimum
r
member size
Engineering Optimization – Concepts and Applications
 Solution procedure
● Compliance minimization problem:

min f T u
ρ

s . t . K (ρ)u  f
V i i  mmax
0   min   i  1
● Solved by:

– Constrained optimization algorithms

(convex approximation methods: SLP, MMA)
– Optimality criteria methods (heuristic)

Engineering Optimization – Concepts and Applications

 Do it yourself!
F

● See www.topopt.dtu.dk!

– Online optimization

– Matlab programs

Engineering Optimization – Concepts and Applications

 Recent progress in
other applications
● Topology optimization techniques
also (being) developed for:
– Multi-material designs, shells, 3D structures

– Compliant mechanism design (large displacements)

– Thermal actuator design (MEMS)

– Crashworthiness design

– PZT actuator design

– Shape memory alloy actuator design

Engineering Optimization – Concepts and Applications

 Compliant mechanisms
● Precise, frictionless motion,
single structure (no joints)
● Lu et al, 2003

● Wang et al, 2005

Engineering Optimization – Concepts and Applications

 Mechanism design
● Inverter design, Kawamoto/Bendsoe/Sigmund, 2004

Engineering Optimization – Concepts and Applications

 Thermal actuator (Sigmund, 2000)

Engineering Optimization – Concepts and Applications

 Element Connectivity Parameterization
● Topology defined by elements connected with
zero-length links

● Stiffness of links controlled by design variables 

● Elements maintain original properties!

● To reduce number of DOFs, condensation is applied

Uouter
Original
element Uinner
properties

kLi(i)

Engineering Optimization – Concepts and Applications

 Advantages of ECP
● No material model interpolation required

● Straightforward sensitivity analysis

● No numerical instabilities due to excessive distortion of weak elements 1:

Extreme
Reference Density-based distortion ECP

F1

F2

1
) Yoon and Kim, 2005 Compliant elements

Engineering Optimization – Concepts and Applications

 Shape memory
alloy actuator
● SMA: active material, actuation under temperature
change

SMA
design
domain

Engineering Optimization – Concepts and Applications

 Level sets
● Topology optimization using an implicit boundary
definition as the zero-level contour of a level-set
function

Engineering Optimization – Concepts and Applications

 Geometrically nonlinear mechanism

Compliant
gripper

Element-
density field

Engineering Optimization – Concepts and Applications

 Topology optimization summary
● Very versatile optimization technique:
enormous variety of shapes possible
● Recent development: area of active research

– Improvements (accuracy, efficiency)

– Extensions (nonlinearities, multiple physics, …)

● Try it yourself: topology

optimization Matlab program
topopt.m available on
Blackboard
Engineering Optimization – Concepts and Applications