A level set method for structural topology optimization with multi-constraints and multi-materials

Combining the vector level set model, the shape sensitivity analysis theory with the gradient projection technique, a level set method for topology optimization with multi-constraints and multi-materials is presented in this paper. The method implicitly describes structural material interfaces by the vector level set and achieves the optimal shape and topology through the continuous evolution of the material interfaces in the structure. In order to increase computational efficiency for a fast convergence, an appropriate nonlinear speed mapping is established in the tangential space of the active constraints. Meanwhile, in order to overcome the numerical instability of general topology optimization problems, the regularization with the mean curvature flow is utilized to maintain the interface smoothness during the optimization process. The numerical examples demonstrate that the approach possesses a good flexibility in handling topological changes and gives an interface representation in a high fidelity, compared with other methods based on explicit boundary variations in the literature. The project supported by the National Natural Science Foundation of China (59805001, 10332010) and Key Science and Technology Research Project of Ministry of Education of China (No.104060)     

考虑界面力学性能的组件及结构的协同优化

包含多个内嵌功能组件及支撑结构的多组件结构因其轻量化、多功能等优良特性被广泛应用于航空航天等领域.已有的多组件结构拓扑优化研究大多基于理想界面假设,忽略了材料连接界面可能发生的破坏. 本文针对包含多个内嵌式功能性组件的结构,考虑连接界面的力学性能, 对组件的形状、布局及支撑材料的拓扑进行协同优化,以实现多组件结构的优良承载性能. 首先,基于超椭圆模型对内嵌组件的形状及布局进行显式的参数化描述,并构造其水平集函数表达; 进而,结合组件及支撑材料的水平集拓扑描述、内聚力模型及扩展有限元方法(extended finite element method, XFEM), 在固定网格下对随优化迭代不断演化的结构拓扑及连接界面的力学性能进行准确描述;进一步, 建立水平集法框架下考虑界面力学性能的多组件结构拓扑优化列式,基于伴随变量法推导解析的灵敏度并采用梯度优化算法求解优化问题.本文采用该优化框架分别对内嵌组件的悬臂梁和MBB梁进行协同优化, 在优化过程中,发现组件的初始布局对最终设计有很大的影响, 并且可能导致不良结构.为了避免此情况, 本文提出了两个阶段的优化策略,即首先对组件布局和形状进行优化, 再进行结构和内嵌组件的协同优化.数值结果显示, 在优化结果中功能性组件及界面通常分布于结构受压应力作用的区域,且连接界面最优形状呈现为曲率较小的光滑曲线,该设计避免界面发生拉伸及剪切破坏, 有效提高了结构的承载力,同时也表明了本文所提出考虑连接界面力学性能拓扑优化方法的有效性.      

基于参数化水平集方法的微结构拓扑优化设计

相比于单一材料,复合材料具有轻质高强等优点,拓扑优化方法是设计复合材料的方法之一.本文采用改进的参数化水平集方法,更新了水平集迭代格式,并应用水平集带方法在优化过程中引入中间密度,使水平集方法与变密度法无缝结合以改善水平集方法的拓扑寻优能力,降低其初始设计依赖性.本文以最大化体积模量、剪切模量和负泊松比作为材料设计目标,结合均匀化方法预测材料的宏观等效性能,研究了不同体积分数、多种初始设计及水平集带方法的引入对优化结果的影响,并得到了多种满足不同目标函数的微结构拓扑形式.数值算例验证了本文方法在复合材料微结构设计问题中的有效性.     

基于多相材料的稳态热传导结构轻量化设计

在多相材料的结构拓扑优化问题中,通常给定各相材料体积约束或材料总重量约束作为材料的控制用量.在结构轻量化设计的实际工程背景下,以结构总重量最小化为目标的优化模型具有明确的工程意义.针对含多相材料的稳态传热结构拓扑优化问题,提出了以结构总重量最小化为目标和给定热柔顺度为约束的多工况连续体结构拓扑优化建模方法.遵循独立连续映射建模方式,采用两类独立拓扑变量分别表征单元热传导矩阵和单元重量状态.推导了热柔顺度和总重量对设计变量的敏度,基于一阶和二阶泰勒展开得到各自的近似表达式.通过求解偏微分方程,实现了约束函数一次项过滤,消除了棋盘格现象和网格依赖性问题,并保证了约束方程在过滤后严格成立.建立的近似优化模型具有二次函数形式的目标函数和一次函数形式的约束函数.基于对偶序列二次规划方法对优化模型进行求解直至收敛.通过四个三维结构数值算例分析对比了热柔顺度约束限值、不同材料混合及多工况、多约束条件对优化结果的影响.数值算例结果表明,本文提出的优化方法在基于多相材料的多工况稳态热传导结构轻量化设计中具有可行性和有效性.     

基于空间连续尺寸场的动态均匀化方法

摘 要：提出了基于空间连续尺寸场的动态均匀化方法。方法以均匀化理论为基础,将各向同性蜂窝状微孔结构作为材料描述方式,合理的物理描述自然克服了动态优化中的局部模态现象。不同于将微孔结构尺寸变量依附于单元或节点,采用物质点对应的微孔尺寸为设计变量,基于修正过滤公式的形函数,构造了具有空间连续性的尺寸场,从而克服了棋盘格等数值不稳定性问题。基于复合函数求导法则,推导了总刚度阵、总质量阵等敏度表达式。以动态结构响应量最小化或最大化为目标,体积比为约束,建立了动态结构拓扑优化模型,通过二维结构数值算例对理论方法进行验证。结果表明,方法在连续体结构动态拓扑优化设计中具有可行性和有效。     

基于双向演化的局部水平集组合算法用于拓扑优化

本文基于双向渐进结构优化(BESO)方法和局部水平集方法(LLSM),提出局部水平集组合算法,在拓扑优化中实现双向演化。为改进LLSM的孔洞成核能力,新算法以所提离散水平集函数为节点设计变量,拓扑导数为灵敏度,按照BESO优化准则进行双向演化得到稳定拓扑解。然后通过迭代求解距离正则化方程(DRE)来组合LLSM获得最终拓扑。在LLSM中,DRE用来代替重生成步骤,并构造条件稳定差分格式求解DRE。最终给出典型实例验证所提算法的收敛性和数值稳定性。     

A structural topological optimization method for multi-displacement constraints and any initial topology configuration

In density-based topological design, one expects that the final result consists of elements either black （solid material） or white （void）, without any grey areas. Moreover, one also expects that the optimal topology can be obtained by starting from any initial topology configuration. An improved structural topological optimization method for multidisplacement constraints is proposed in this paper. In the proposed method, the whole optimization process is divided into two optimization adjustment phases and a phase transferring step. Firstly, an optimization model is built to deal with the varied displacement limits, design space adjustments, and reasonable relations between the element stiffness matrix and mass and its element topology variable. Secondly, a procedure is proposed to solve the optimization problem formulated in the first optimization adjustment phase, by starting with a small design space and advancing to a larger deign space. The design space adjustments are automatic when the design domain needs expansions, in which the convergence of the proposed method will not be affected. The final topology obtained by the proposed procedure in the first optimization phase, can approach to the vicinity of the optimum topology. Then, a heuristic algorithm is given to improve the efficiency and make the designed structural topology black/white in both the phase transferring step and the second optimization adjustment phase. And the optimum topology can finally be obtained by the second phase optimization adjustments. Two examples are presented to show that the topologies obtained by the proposed method are of very good 0/1 design distribution property, and the computational efficiency is enhanced by reducing the element number of the design structural finite model during two optimization adjustment phases. And the examples also show that this method is robust and practicable.     

多工况下结构拓扑优化设计

考虑单元删除和增加对结构应力约束的影响，提出了一种新的多工况下结构的双方向渐进优化方法．首先，基于在结构孔洞或边界周围附加人工材料的思路，建立了结构优化模型和应力灵敏度公式．然后，结合结构应力和应力灵敏度，给出了多工况静力载荷下考虑静应力约束的结构优化准则和算法．开展了结构仿真设计，结果表明给出的方法是正确和有效的，并具有较好的工程应用价值．     

Stiffness and strength of hierarchical polycrystalline materials with imperfect interfaces

In this study we investigate the effect of imperfect (not perfectly bonded) interfaces on the stiffness and strength of hierarchical polycrystalline materials. As a case study we consider a honeycomb cellular polycrystal used for drilling and cutting tools. The conclusions of the analysis are, however, general and applicable to any material with structural hierarchy. Regarding the stiffness, generalized expressions for the Voigt and Reuss estimates of the bounds to the effective elastic modulus of heterogeneous materials are derived. The generalizations regard two aspects that are not included in the standard Reuss and Voigt estimates. The first novelty consists in considering finite thickness interfaces between the constituents undergoing damage up to final debonding. The second generalization consists of interfaces not perpendicular or parallel to the loading direction, i.e., when isostress or isostrain conditions are not satisfied. In this case, approximate expressions for the effective elastic modulus are obtained by performing a computational homogenization approach. In the second part of the paper, the homogenized response of a representative volume element (RVE) of the honeycomb cellular polycrystalline material with one or two levels of hierarchy is numerically investigated. This is put forward by using the cohesive zone model (CZM) for finite thickness interfaces recently proposed by the authors and implemented in the finite element program FEAP. From tensile tests we find that the interface nonlinearity significantly contributes to the deformability of the material. Increasing the number of hierarchical levels, the deformability increases. The RVE is tested in two different directions and, due to different orientations of the interfaces and Mixed Mode deformation, anisotropy in stiffness and strength is observed. Stiffness anisotropy is amplified by increasing the number of hierarchical levels. Finally, the interaction between interfaces at different hierarchical levels is numerically characterized. A condition for scale separation, which corresponds to the independence of the material tensile strength from the properties of the interfaces in the second level, is established. When this condition is fulfilled, the material microstructure at the second level can be efficiently replaced by an effective homogeneous continuum with a homogenized stress–strain response. From the engineering point of view, the proposed criterion of scale separation suggests how to design the optimal microstructure of a hierarchical level to maximize the material tensile strength. An interpretation of this phenomenon according to the concept of flaw tolerance is finally presented.     

传热结构的多目标拓扑优化设计研究

深入分析了传热结构多目标拓扑优化设计中的几个关键问题。提出了基于结构柔度最小化和结构散热弱度最小化的多目标拓扑优化设计方法,建立了传热结构的多目标拓扑优化设计模型,推导了传热结构多目标拓扑优化中用于迭代分析求解的优化准则算法和敏度分析方程。通过数值计算验证了理论和算法的有效性。     

基于热固耦合问题的多尺度拓扑优化设计

基于均质材料的拓扑优化逐渐难以适应现代化生产对工业产品高品质、轻量化的需求,同时很多工业设备经常面临着高温和高负载的工作环境.为了提高结构在温度载荷和机械载荷共同作用下的力学性能,本文提出了一种在稳态热源作用下的热固耦合连续体结构并行化拓扑优化方法.以结构刚度作为目标函数,材料的体分比为约束,利用能量均匀化方法预测微结构的等效属性,建立热固耦合结构并行化拓扑优化数学模型.为便于数值计算,利用直接法进行灵敏度分析,同时采用Heaviside非线性密度过滤技术抑制数值不稳定性,将OC准则算法用于求解优化问题.数值算例表明,本文方法能够有效地进行优化设计且能显著地提高结构的刚度性能和散热性能.     

基于网格退化和重组技术的类桁架拓扑优化方法

发展了一种基于有限元网格退化和重组技术的类桁架拓扑优化方法,可在不改变设计域包络的情况下(如维持流型、艺术外观和附加功能等)对结构进行减重。首先,分别对二维问题和三维问题发展相应的有限元网格退化算法,并在刚度等效的意义上对网格进行重组,建立了具有杆元拓扑特征的有限元模型。其次,以全局种子网格的长度尺寸和杆元横截面积为优化变量,构造了域内双层驱动拓扑优化问题,得到具有最优体分比的杆元拓扑结构。数值算例表明,所提方法可获得新型式的结构拓扑优化方案,并可将结构拓扑优化理论推向工程化应用。     

Structural interfaces in linear elasticity. Part I: Nonlocality and gradient approximations

Many biological and optimal materials, at multiple scales, consist of what can be idealized as continuous bodies joined by structural interfaces. Mechanical characterization of the microstructure defining the interface can nowadays be accurately done; however, such interfaces are usually analyzed employing models where those properties are overly simplified. To introduce into the analysis the microstructure properties, a new model of structural interfaces is proposed and developed: a true structure is introduced in the transition zone, joining continuous bodies, with geometrical and material properties directly obtained from those of the interfacial microstructure. First, the case of an elliptical inclusion connected by a structural interface to an infinite matrix is solved analytically, showing that nonlocal effects follow directly from the introduction of the structure, related to the inclination of the connecting elements. Second, starting from a discrete structure, a continuous model of a structural interface is derived. The usual zero-thickness linear interface model is shown to be a special case of this more general continuous structural interface model. Then, a gradient approximation of the interface constitutive law is rigorously derived: it is the first example of the analytical derivation of a nonlocal interface model from the microstructure properties. The effects introduced in the mechanical behavior by both the continuous model and its gradient approximation are illustrated by solving, for the first time, the problem of a circular inclusion connected to an infinite matrix by a structural interface and subject to remote uniform stress.     

多相材料传热微结构的多目标优化设计

提出基于散热弱度的材料微结构热传导性能的预测方法,分别从理论和数值上验证该方法与均匀化方法的等效性;推导出微结构等效热传导系数的灵敏度计算格式,建立传热微结构拓扑优化的数学模型.以二维、三维多相材料等效热传导系数的加权组合为目标,采用凸规划对偶优化算法和二次型周长约束进行材料微结构的设计和材料分布的棋盘格控制.数值算例表明基于散热弱度的传热材料微结构设计是可行、有效的,可以为实际的材料设计提供依据.     

频率约束的三维连续体结构动力拓扑优化设计

针对频率约束和结构重量最小的动力拓扑优化问题, 基于(independent continuous mapping, ICM)独立、连续、映射方法,建立了频率约束下的三维连续体拓扑优化模型. 利用瑞利商和一阶泰勒展式对频率约束进行了显式化处理,并采用幂函数与复合指数函数作为过滤函数,将优化模型进行了标准化转换, 利用对偶理论及数学规划法进行了求解. 另外,利用质量矩阵和刚度矩阵过滤函数比值与动态约束处理了局部模态和模态交换等数值问题. 最后,通过应用两类不同过滤函数的数值算例表明了文中模型及方法在处理动力拓扑优化问题上的合理性与有效性.      

基于遗传算法的复合材料细观结构拓扑优化设计

利用高精度通用单胞模型将复合材料的细观拓扑结构与宏观力学性能结合起来,采用遗传算法对复合材料的细观结构进行优化,发展了基于遗传算法的复合材料细观结构拓扑优化设计方法.以材料的宏观力学性能为优化目标,从随机的初始细观结构出发,对复合材料纤维体积百分比进行约束,经过迭代获得满足设计要求的代表性体积单元.在优化过程中,对遗传算法的交叉过程作了较大的改进,实现了复合材料细观拓扑结构的任意变化,提高了对可行域的搜索效率.分别以极限剪切模量和泊松比为优化目标,验证了所提出优化方法的正确性和有效性.     

应力约束全局化策略下的连续体结构拓扑优化

利用Mises强度理论，提出了应力约束全局化策略，将局 部的应力约束问题转化为结构整体的应变能约束问题. 基于ICM(独立、连续、映射)方法， 引入了独立、连续的拓扑变量，对单元重量、单元刚度和单元许用应力的过滤函数进行了选 择，建立了以重量为目标，以结构应变能代替应力约束的多工况下连续体结构拓扑优化模型， 寻找到了多工况下的最佳传力路径. 运用对偶二次规划方法对上述优化模型进行了求解. 另 外，利用PCL语言，在MSC/PATRAN的开发平台上，实现了应用应力约束全局化策略进行连 续体结构拓扑优化的模块化处理. 数值算例表明了该方法的可行性和有效性.     

考虑最小尺寸精确控制的SIMP和MMC混合拓扑优化方法

拓扑优化作为一种先进设计方法, 已被成功用于多个学科领域优化问题求解, 但从拓扑优化结果到其工程应用之间仍存在诸多阻碍, 如在结构设计中存在难以制造的小孔或边界裂缝和单铰链连接等. 在拓扑优化设计阶段考虑结构最小尺寸控制是解决上述问题的一种有效手段. 在最小尺寸控制的结构拓扑优化方法中, 通用性较强的固体各向同性材料惩罚法SIMP优化结果边界模糊不光滑, 包含精确几何信息的移动变形组件法MMC对初始布局具有较强依赖性. 本文提出一种考虑最小尺寸精确控制的SIMP和MMC混合拓扑优化方法. 所提方法继承了二者优势, 避免了各自缺点. 在该方法中, 首先采用活跃轮廓算法ACWE获取SIMP输出的拓扑结构边界轮廓数据, 提出了SIMP优化结果到MMC组件初始布局的映射方法. 其次, 通过引入组件的3个长度变量, 建立了半圆形末端的多变形组件拓扑描述函数模型. 最后, 以组件厚度变量为约束, 构建了考虑结构最小尺寸控制的拓扑优化模型. 采用最小柔度问题和柔性机构问题验证了所提方法的有效性. 数值结果表明, 所提方法在无需额外约束的条件下, 仅通过组件厚度变量下限设置, 可实现整体结构的最小尺寸精确控制, 并获得了具有全局光滑的拓扑结构边界.