Large-Scale Three-Dimensional Anisotropic Topology Optimization of Variable-Axial Composite Structures

2021 ◽  
Author(s):  
Kazuhiro Saitou ◽  
Yuqing Zhou ◽  
Tsuyoshi Nomura ◽  
Wei Zhang ◽  
Enpei Zhao
Keyword(s):  
Topology Optimization ◽  
Composite Structures ◽  
Large Scale ◽  
Three Dimensional

Large-scale three-dimensional anisotropic topology optimization of variable-axial lightweight composite structures

2021 ◽  
pp. 1-15
Author(s):  
Yuqing Zhou ◽  
Tsuyoshi Nomura ◽  
Enpei Zhao ◽  
Kazuhiro Saitou
Keyword(s):  
Topology Optimization ◽  
Composite Structures ◽  
Large Scale ◽  
Volume Fraction ◽  
Three Dimensional ◽  
Optimization Method ◽  
Optimized Design ◽  
Adaptive Meshing ◽  
Design Synthesis ◽  
Fiber Placement

Abstract Variable-axial fiber-reinforced composites allow for local customization of fiber orientation and thicknesses. Despite their significant potential for performance improvement over the conventional multiaxial composites and metals, they pose challenges in design optimization due to the vastly increased design freedom in material orientations. This paper presents an anisotropic topology optimization method for designing large-scale, 3D variable-axial lightweight composite structures subject to multiple load cases. The computational challenges associated with large-scale 3D anisotropic topology optimization with extremely low volume fraction are addressed by a tensor-based representation of 3D orientation that would avoid the 2π periodicity of angular representations such as Euler angles, and an adaptive meshing scheme, which, in conjunction with PDE regularization of the density variables, refines the mesh where structural members appear and coarsens where there is void. The proposed method is applied to designing a heavy-duty drone frame subject to complex multi-loading conditions. Finally, the manufacturability gaps between the optimized design and the fabrication-ready design for Tailored Fiber Placement (TFP) is discussed, which motivates future work toward a fully-automated design synthesis.

Large-Scale Three-Dimensional Anisotropic Topology Optimization of Variable-Axial Composite Structures

2020 ◽  
Author(s):  
Yuqing Zhou ◽  
Tsuyoshi Nomura ◽  
Enpei Zhao ◽  
Wei Zhang ◽  
Kazuhiro Saitou
Keyword(s):  
Topology Optimization ◽  
Composite Structures ◽  
Large Scale ◽  
Volume Fraction ◽  
Three Dimensional ◽  
Optimized Design ◽  
Adaptive Meshing ◽  
Design Synthesis ◽  
Fiber Placement ◽  
Future Work

Abstract Variable-axial fiber-reinforced composites allow for local customization of fiber orientation and thicknesses. Despite their significant potential for performance improvement over the conventional multiaxial composites and metals, they pose challenges in design optimization due to the vastly increased design freedom in material orientations. This paper presents an anisotropic topology optimization (TO) method for designing large-scale, 3D variable-axial composite structures. The computational challenge for large-scale 3D TO with extremely low volume fraction is addressed by a tensor-based representation of 3D orientation that would avoid the 2π periodicity of angular representation such as Eular angles, and an adaptive meshing scheme, which, in conjunction with PDE regularization of the density variables, refines the mesh where structural members appear and coarsens where there is void. The proposed method is applied to designing a heavy-duty drone frame subject to complex multi-loading conditions. Finally, the manufacturability gaps between the optimized design and the fabrication-ready design for Tailored Fiber Placement (TFP) is discussed, which motivates future work toward fully-automated design synthesis.

scholarly journals Stereological Estimation of Orientation Distribution of Generalized Cylinders from a Unique 2D Slice

2013 ◽  
Vol 19 (6) ◽  
pp. 1678-1687 ◽  
Author(s):  
Jean-Pierre Da Costa ◽  
Stefan Oprean ◽  
Pierre Baylou ◽  
Christian Germain
Keyword(s):  
Cross Sections ◽  
Composite Structures ◽  
Large Scale ◽  
Fibrous Composite ◽  
Three Dimensional ◽  
Synthetic Data ◽  
Inequality Constraints ◽  
Orientation Distribution ◽  
Industrial Applications ◽  
Cost Constraints

AbstractThough three-dimensional (3D) imaging gives deep insight into the inner structure of complex materials, the stereological analysis of 2D snapshots of material sections is still necessary for large-scale industrial applications for reasons related to time and cost constraints. In this paper, we propose an original framework to estimate the orientation distribution of generalized cylindrical structures from a single 2D section. Contrary to existing approaches, knowledge of the cylinder cross-section shape is not necessary. The only requirement is to know the area distribution of the cross-sections. The approach relies on minimization of a least squares criterion under linear equality and inequality constraints that can be solved with standard optimization solvers. It is evaluated on synthetic data, including simulated images, and is applied to experimental microscopy images of fibrous composite structures. The results show the relevance and capabilities of the approach though some limitations have been identified regarding sensitivity to deviations from the assumed model.

scholarly journals The influence of uncertain loading on topology-optimized designs

2021 ◽  
Author(s):  
Philipp Hofer ◽  
Erich Wehrle
Keyword(s):  
Topology Optimization ◽  
Open Source ◽  
Large Scale ◽  
Three Dimensional ◽  
Applied Force ◽  
Structural Performance ◽  
Optimized Design ◽  
Applied Forces ◽  
Reducing Costs ◽  
The Relationship

The design of structures using topology optimization can improve the structural performance and save material, in turn reducing costs. Using a framework of large-scale, three-dimensional topology optimization implemented by the authors in an open-source multiphysical software, we investigate the influence of uncertain loading on the optimized design. Direct differentiation is used to reveal the relationship between displacements and applied force, giving an efficient and effective tool to postprocess optimized topologies. The developed methodology for the assessment of the sensitivity with respect to applied forces is explored using two three-dimensional examples: the classic MBB cantilever and a cableway pylon. The advantages and limitations of this method are discussed.

Three-Dimensional Layout Design of Steel-Concrete Composite Structures Using Topology Optimization

2011 ◽  
Vol 308-310 ◽  
pp. 886-889 ◽  
Author(s):  
Yang Jun Luo ◽  
Xiao Xiang Wu ◽  
Alex Li
Keyword(s):  
Topology Optimization ◽  
Composite Structures ◽  
Three Dimensional ◽  
Material Model ◽  
Structural Topology ◽  
Numerical Result ◽  
Gradient Based ◽  
Optimization Methodology ◽  
Optimal Material ◽  
Displacement Constraints

For generating a more reasonable initial layout configuration, a three-dimensional topology optimization methodology of the steel-concrete composite structure is presented. Following Solid Isotropic Material with Penalization (SIMP) approach, an artificial material model with penalization for elastic constants is assumed and elemental density variables are used for describing the structural layout. The considered problem is thus formulated as to find the optimal material density distribution that minimizes the material volume under specified displacement constraints. By using the adjoint variable method for the sensitivity analysis, the optimization problem is efficiently solved by the gradient-based optimization algorithm. Numerical result shows that the proposed topology approach presented a novel structural topology of the simply-supported steel-concrete composite beam.

scholarly journals Nonlinear analysis of multilayer composite pipes

2019 ◽  
Author(s):  
DC Pham
Keyword(s):  
Composite Structures ◽  
Large Scale ◽  
Global Analysis ◽  
Three Dimensional ◽  
Axial Loading ◽  
Large Scale Analysis ◽  
External Pressures ◽  
Highly Nonlinear ◽  
Composite Pipe ◽  
Composite Pipes

The use of composite materials has constantly increased in aerospace and offshore applications. One of typical composite structures for offshore application is multilayer unbonded composite pipe. The composite pipe comprised of several layers such as helically wound steel layers and polymeric layers, among which the helically wound steel wires play essential roles in providing axial and flexural stiffnesses of the pipe. Because of the geometric nonlinearity of each layer of the composite pipe and the flexibility in motion of individual layers against their adjacent layers, analyses of the composite pipe are highly nonlinear and computationally challenging. In this study, detailed three-dimensional Representative Volume Element models of the multilayer unbonded composite pipe are developed, and nonlinear analyses of the composite pipe are performed. The developed FE models effectively predict nonlinear responses of the pipe including slipping effects of steel layers under application of axial loading, bending, internal and external pressures. Based on the predicted results, a constitutive model of the pipe under various loadings is obtained which can be employed in the large scale analysis of the composite pipe to improve the accurate and computational efficiency of the global analysis.

Large Scale Topology Optimization of 3D Static Mixers

2020 ◽  
Author(s):  
Sicheng Sun ◽  
Jaal Ghandhi ◽  
Xiaoping Qian
Keyword(s):  
Topology Optimization ◽  
Pressure Drop ◽  
Cross Section ◽  
Large Scale ◽  
Three Dimensional ◽  
Navier Stokes ◽  
Straight Channel ◽  
Navier Stokes Equation ◽  
Static Mixers ◽  
Static Fluid

Abstract Topology optimization (TO) was conducted for three dimensional static fluid mixers. The problem is optimized using the weakly coupled Navier-Stokes equation at low Reynolds number (Re ≤ 1) and a convection-diffusion equation. The domain was discretized with up to 10 million cells. The optimizations were run with 1024 to 2048 CPUs on a national supercomputer. For a mixer in a square cross-section channel, the mixing was improved by 83% for a modest 2.5 times higher pressure drop compared with the open straight channel. For a cylindrical cross-section tee arrangement, the mixing improved by 91% with a 2.5 times higher pressure drop compared to the straight channel.

scholarly journals Topology Optimization of Large-Scale 3D Morphing Wing Structures

Actuators ◽  
2021 ◽  
Vol 10 (9) ◽  
pp. 217
Author(s):  
Peter Dørffler Ladegaard Jensen ◽  
Fengwen Wang ◽  
Ignazio Dimino ◽  
Ole Sigmund
Keyword(s):  
Topology Optimization ◽  
Large Scale ◽  
Three Dimensional ◽  
Material Model ◽  
Optimization Approach ◽  
Morphing Wing ◽  
Feature Mapping ◽  
Three Phase ◽  
Wing Structures ◽  
Structural Compliance

This work proposes a systematic topology optimization approach for simultaneously designing the morphing functionality and actuation in three-dimensional wing structures. The actuation was modeled by a linear-strain-based expansion in the actuation material. A three-phase material model was employed to represent structural and actuating materials and voids. To ensure both structural stiffness with respect to aerodynamic loading and morphing capabilities, the optimization problem was formulated to minimize structural compliance, while the morphing functionality was enforced by constraining a morphing error between the actual and target wing shape. Moreover, a feature-mapping approach was utilized to constrain and simplify the actuator geometries. A trailing edge wing section was designed to validate the proposed optimization approach. Numerical results demonstrated that three-dimensional optimized wing sections utilize a more advanced structural layout to enhance structural performance while keeping the morphing functionality better than two-dimensional wing ribs. The work presents the first step towards the systematic design of three-dimensional morphing wing sections.

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