This review paper provides an overview of different level-set methods for structural topology optimization. Level-set methods can be categorized with respect to the level-set-function ...parameterization, the geometry mapping, the physical/mechanical model, the information and the procedure to update the design and the applied regularization. Different approaches for each of these interlinked components are outlined and compared. Based on this categorization, the convergence behavior of the optimization process is discussed, as well as control over the slope and smoothness of the level-set function, hole nucleation and the relation of level-set methods to other topology optimization methods. The importance of numerical consistency for understanding and studying the behavior of proposed methods is highlighted. This review concludes with recommendations for future research.
Solving conjugate heat transfer design problems is relevant for various engineering applications requiring efficient thermal management. Heat exchange between fluid and solid can be enhanced by ...optimizing the system layout and the shape of the flow channels. As heat is transferred at fluid/solid interfaces, it is crucial to accurately resolve the geometry and the physics responses across these interfaces. To address this challenge, this work investigates for the first time the use of an eXtended Finite Element Method (XFEM) approach to predict the physical responses of conjugate heat transfer problems considering turbulent flow. This analysis approach is integrated into a level set-based optimization framework. The design domain is immersed into a background mesh and the geometry of fluid/solid interfaces is defined implicitly by one or multiple level set functions. The level set functions are discretized by higher-order B-splines. The flow is predicted by the Reynolds Averaged Navier–Stokes equations. Turbulence is described by the Spalart–Allmaras model and the thermal energy transport by an advection–diffusion model. Finite element approximations are augmented by a generalized Heaviside enrichment strategy with the state fields being approximated by linear basis functions. Boundary and interface conditions are enforced weakly with Nitsche’s method, and the face-oriented ghost stabilization is used to mitigate numerical instabilities associated with the emergence of small integration subdomains. The proposed XFEM approach for turbulent conjugate heat transfer is validated against benchmark problems. Optimization problems are solved by gradient-based algorithms and the required sensitivity analysis is performed by the adjoint method. The proposed framework is illustrated with the design of turbulent heat exchangers in two dimensions. The optimization results show that, by tuning the shape of the fluid/solid interface to generate turbulence within the heat exchanger, the transfer of thermal energy can be increased.
By altering the structural shape and fiber orientation, this research aims to optimize the design of Fiber-Reinforced Composite (FRC) structures. The structural geometry is represented by a level set ...function approximated by quadratic B-spline functions. The fiber orientation field is parameterized with quadratic/cubic B-splines on hierarchically refined meshes. Different levels for B-spline mesh refinement for the level set and fiber orientation fields are studied to resolve geometric features and to obtain a smooth fiber layout. To facilitate FRC manufacturing, the parallel alignment and smoothness of fiber paths are enforced by introducing penalty terms referred to as "misalignment penalty" and "curvature penalty". A geometric interpretation of these penalties is provided. The material behavior of the FRCs is modeled by the Mori–Tanaka homogenization scheme and the macroscopic structure response is predicted by linear elasticity under static multiloading conditions. The governing equations are discretized by a Heaviside-enriched eXtended IsoGeometric Analysis (XIGA) to avoid the need to generate conformal meshes. Instabilities in XIGA are mitigated by the face-oriented ghost stabilization technique. This work considers mass and strain energy in the formulation of the optimization objective, along with misalignment and curvature penalties and additional regularization terms. Constraints are imposed on the volume of the structure. The resulting optimization problems are solved by a gradient-based algorithm. The design sensitivities are computed by the adjoint method. Numerical examples demonstrate with two-dimensional and three-dimensional configurations that the proposed method is efficient in simultaneously optimizing the macroscopic shape and the fiber layout while improving manufacturability by promoting parallel and smooth fiber paths.
Multi-material problems often exhibit complex geometries along with physical responses presenting large spatial gradients or discontinuities. In these cases, providing high-quality body-fitted finite ...element analysis meshes and obtaining accurate solutions remain challenging. Immersed boundary techniques provide elegant solutions for such problems. Enrichment methods alleviate the need for generating conforming analysis grids by capturing discontinuities within mesh elements. Additionally, increased accuracy of physical responses and geometry description can be achieved with higher-order approximation bases. In particular, using B-splines has become popular with the development of IsoGeometric Analysis. In this work, an eXtended IsoGeometric Analysis (XIGA) approach is proposed for multi-material problems. The computational domain geometry is described implicitly by level set functions. A novel generalized Heaviside enrichment strategy is employed to accommodate an arbitrary number of materials without artificially stiffening the physical response. Higher-order B-spline functions are used for both geometry representation and analysis. Boundary and interface conditions are enforced weakly via Nitsche’s method, and a new face-oriented ghost stabilization methodology is used to mitigate numerical instabilities arising from small material integration subdomains. Two- and three-dimensional heat transfer and elasticity problems are solved to validate the approach. Numerical studies provide insight into the ability to handle multiple materials considering sharp-edged and curved interfaces, as well as the impact of higher-order bases and stabilization on the solution accuracy and conditioning.
Ill-conditioning of the system matrix is a well-known complication in immersed finite element methods and trimmed isogeometric analysis. Elements with small intersections with the physical domain ...yield problematic eigenvalues in the system matrix, which generally degrades efficiency and robustness of iterative solvers. In this contribution we investigate the spectral properties of immersed finite element systems treated by Schwarz-type methods, to establish the suitability of these as smoothers in a multigrid method. Based on this investigation we develop a geometric multigrid preconditioner for immersed finite element methods, which provides mesh-independent and cut-element-independent convergence rates. This preconditioning technique is applicable to higher-order discretizations, and enables solving large-scale immersed systems at a computational cost that scales linearly with the number of degrees of freedom. The performance of the preconditioner is demonstrated for conventional Lagrange basis functions and for isogeometric discretizations with both uniform B-splines and locally refined approximations based on truncated hierarchical B-splines.
Abstract
A new formulation for the displacement‐only partitioned equations of motion for linear structures is presented, which employs: the partitioned displacement, acceleration, and applied force ...(); the partitioned block diagonal mass and stiffness matrices (); and, the coupling projector (), yielding the partitioned coupled equations of motion: ). The key element of the proposed formulation is the coupling projector () which can be constructed with the partitioned mass matrix (), the Boolean matrix that extracts the partition boundary degrees of freedom (), and the assembly matrix () relating the assembled displacements () to the partitioned displacements () via . Potential utility of the proposed formulation is illustrated as applied to six proof‐of‐concept problems in an ideal setting: unconditionally stable explicit‐implicit transient analysis, static parallel analysis in an iterative solution mode; reduced‐order modeling (component mode synthesis); localized damage identification which can pinpoint damage locations; a new procedure for partitioned structural optimization; and, partitioned modeling of multiphysics problems. Realistic applications of the proposed formulation are presently being carried out and will be reported in separate reports.
Fluid–structure interaction phenomena are often roughly approximated when the stochastic nature of a system is considered in the design optimization process, leading to potentially significant ...epistemic uncertainty. In this paper, after reviewing the state-of-the-art methods in robust and reliability-based design optimization of problems undergoing fluid–structure interaction phenomena, a computational framework is presented that integrates a high-fidelity aeroelastic model into reliability-based design optimization. The design optimization problem is formulated pursuant to the reliability index and performance measure approaches. The system reliability is evaluated by a first-order reliability analysis method. The steady-state aeroelastic problem is described by a three-field formulation and solved by a staggered procedure, coupling a potentially detailed structural finite element model and a finite volume discretization of the Euler flow. The design and imperfection sensitivities are computed by evaluating the analytically derived direct and adjoint coupled aeroelastic sensitivity equations. The computational framework is verified by the optimization of three-dimensional wing structures. The lift-to-drag ratio is maximized, subject to stress constraints, by varying shape, thickness, and material properties. Uncertainties in structural parameters, including design parameters, operating conditions, and modeling uncertainties are considered. The results demonstrate the need for reliability-based optimization methods, for the design of structures undergoing fluid–structure interaction phenomena, and the applicability of the proposed framework to realistic design problems. Comparing the optimization results for different levels of uncertainty shows the importance of accounting for uncertainties in a quantitative manner.
Aeroelastic phenomena are most often either ignored or roughly approximated when uncertainties are considered in the design optimization process of structures subject to aerodynamic loading, ...affecting the quality of the optimization results. Therefore, a design methodology is proposed that combines reliability-based design optimization and high-fidelity aeroelastic simulations for the analysis and design of aeroelastic structures. To account for uncertainties in design and operating conditions, a first-order reliability method (FORM) is employed to approximate the system reliability. To limit model uncertainties while accounting for the effects of given uncertainties, a high-fidelity nonlinear aeroelastic simulation method is used. The structure is modelled by a finite element method, and the aerodynamic loads are predicted by a finite volume discretization of a nonlinear Euler flow. The usefulness of the employed reliability analysis in both describing the effects of uncertainties on a particular design and as a design tool in the optimization process is illustrated. Though computationally more expensive than a deterministic optimum, due to the necessity of solving additional optimization problems for reliability analysis within each step of the broader design optimization procedure, a reliability-based optimum is shown to be an improved design. Conventional deterministic aeroelastic tailoring, which exploits the aeroelastic nature of the structure to enhance performance, is shown to often produce designs that are sensitive to variations in system or operational parameters.
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