Multi-Material and Multi-Joint Topology Optimization for Lightweight and Cost-Effective Design

2021 ◽  
Author(s):  
Luke Crispo ◽  
Stephen William Knox Roper ◽  
Rubens Bohrer ◽  
Rosalie Morin ◽  
Il Yong Kim
Keyword(s):  
Topology Optimization ◽  
Dissimilar Materials ◽  
Cost Effective ◽  
Unstructured Meshes ◽  
Parameter Study ◽  
Design Variables ◽  
Research Themes ◽  
Multiple Material ◽  
Optimization Methodology ◽  
Effective Design

Abstract Lightweighting and cost reduction are overarching research themes in aerospace and automotive industries, leading to the exploration of new materials, advanced manufacturing methods, and design optimization algorithms. Multi-material topology optimization is an important tool that can generate unconventional designs leveraging the differing mechanical properties of multiple material types to increase performance. However, these approaches do not consider joining design during optimization, which can ultimately result in higher cost, worse performance, and unrealistic designs that must be altered in the interpretation stage. This work presents a multi-material and multi-joint topology optimization methodology that models joints at the interfaces between dissimilar materials, controls the joining pattern using joint design variables, and reduces cost through the addition of a joining cost constraint. Design variable interpolation schemes, interface detection for unstructured meshes, and sensitivity analysis are outlined in detail in this paper. The approach is applied to a real-world rocker arm geometry to demonstrate the importance of considering joints during multi-material topology optimization. The results of the numerical example indicate that the methodology can successfully detect interfaces in unstructured meshes and strategically place joints to maximize stiffness of the structure. A parameter study of various joining cost constraint levels illustrates how the optimizer alters part topology and joining design to reduce cost.

Cost-Optimal Design of Dry Cooling Towers Through Mathematical Programming Techniques

1989 ◽  
Vol 111 (2) ◽  
pp. 322-327 ◽  
Author(s):  
J. D. Buys ◽  
D. G. Kro¨ger
Keyword(s):  
Objective Function ◽  
Cooling System ◽  
Cost Effective ◽  
Operating Conditions ◽  
Variable Metric ◽  
Design Variables ◽  
Specific Performance ◽  
Programming Techniques ◽  
Effective Design ◽  
Dry Cooling

The Constrained Variable Metric Algorithm is chosen to minimize the objective function (cost) in the design of a natural draft dry cooling tower. An existing cooling system design that has specific performance characteristics under prescribed operating conditions is selected as a reference unit. By changing design variables, but not exceeding prescribed constraints, a more cost-effective design is achieved. The influence of various parameters, and the sensitivity of the objective function to these parameters, are evaluated.

scholarly journals Sensitivity analysis of conformal CCs for injection molds: 2D Transient Heat Transfer Analysis

2021 ◽  
Author(s):  
Hugo Miguel Silva ◽  
Tiago Noversa ◽  
Leandro Fernandes ◽  
Hugo Rodrigues ◽  
António Pontes
Keyword(s):  
Sensitivity Analysis ◽  
Injection Molding ◽  
Thermal Stresses ◽  
Parametric Design ◽  
Cost Effective ◽  
Heat Transfer Analysis ◽  
Ejection Time ◽  
Cooling Channels ◽  
Design Variables ◽  
Optimization Methodology

Abstract Conformal Cooling Channels (CCCs) have gotten easier and more economical to manufacture in recent years. This was largely due to recent developments in additive manufacturing. The usage of CCCs in engineering applications involving injection molding provides for superior cooling performance than straight drilled channels, which have traditionally been utilized in injection molding. The fundamental reason for this is that CCCs are able to follow the molded geometry's trajectories. With the use of CCC’s, the cooling time, total injection time, thermal stresses, and warpage can all be considerably reduced. Nonetheless, the CCC design process is more difficult than that of traditional channels. The integration of computer-aided engineering (CAE) simulations is critical for achieving an effective, cost-effective design. This paper focuses the sensitivity analysis of design variables, with the intention of implementing a design optimization methodology in the future. The ultimate goal is to optimize the placement of Cooling Channels (CCs) to minimize the ejection time and maximize the uniformity of temperature distribution. It can be concluded that the parametrization done in ANSYS Parametric Design Language (APDL), as well as the selected design variables are feasible and might be useful for future optimization methodologies.

Structural optimization of a composite launch tube of man portable air defense system

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Efecan Yar ◽  
Erdem Acar
Keyword(s):  
Structural Optimization ◽  
Minimum Weight ◽  
Cost Effective ◽  
Defense System ◽  
Content Type ◽  
Air Defense ◽  
Design Variables ◽  
Optimum Cost ◽  
Effective Design ◽  
Launch Tube

Purpose The purpose of this paper is to find the optimum configuration of the composite launch tube currently being developed in Roketsan. The winding thicknesses and winding angles of the launch tube are selected as design variables, and three different composite material alternatives are evaluated: glass/epoxy, carbon/epoxy and aramid/epoxy. Design/methodology/approach In this study, structural optimization of a composite launch tube of man portable air defense system is conducted. To achieve a cost-effective design, a cost scoring table that includes structural weight, material cost, availability and manufacturability is first introduced. Then, optimization for minimum weight is conducted, where the winding thicknesses and winding angle are taken as design variables, and the safety factor value obtained by using the Tsai–Wu damage criterion is used as constraint. A surrogate-based optimization approach is used where various options for surrogate models are evaluated. Glass/epoxy, carbon/epoxy and aramid/epoxy are considered as alternative materials for the launch tube. Finally, the selection of the most cost-effective design is performed to achieve optimum cost. Findings Carbon fiber-reinforced epoxy matrix material provides the optimum cost-effective design for the launch tube. Practical implications The findings of the paper can be used to design more cost-efficient composite launch tube currently being developed in Roketsan. Originality/value The existing studies are based on a design approach to achieve minimum weight of the launch tubes, whereas this study introduces a design approach to achieve optimum cost.

scholarly journals Topology Optimization of Hard-Coating Thin Plate for Maximizing Modal Loss Factors

Coatings ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 774
Author(s):  
Haitao Luo ◽  
Rong Chen ◽  
Siwei Guo ◽  
Jia Fu
Keyword(s):  
Topology Optimization ◽  
Objective Function ◽  
Composite Plates ◽  
Optimization Method ◽  
Hard Coating ◽  
Design Variables ◽  
Coating Composite ◽  
Damping Materials ◽  
Topology Optimization Method ◽  
Loss Factors

At present, hard coating structures are widely studied as a new passive damping method. Generally, the hard coating material is completely covered on the surface of the thin-walled structure, but the local coverage cannot only achieve better vibration reduction effect, but also save the material and processing costs. In this paper, a topology optimization method for hard coated composite plates is proposed to maximize the modal loss factors. The finite element dynamic model of hard coating composite plate is established. The topology optimization model is established with the energy ratio of hard coating layer to base layer as the objective function and the amount of damping material as the constraint condition. The sensitivity expression of the objective function to the design variables is derived, and the iteration of the design variables is realized by the Method of Moving Asymptote (MMA). Several numerical examples are provided to demonstrate that this method can obtain the optimal layout of damping materials for hard coating composite plates. The results show that the damping materials are mainly distributed in the area where the stored modal strain energy is large, which is consistent with the traditional design method. Finally, based on the numerical results, the experimental study of local hard coating composites plate is carried out. The results show that the topology optimization method can significantly reduce the frequency response amplitude while reducing the amount of damping materials, which shows the feasibility and effectiveness of the method.

scholarly journals A Sequential Approach for Aerodynamic Shape Optimization with Topology Optimization of Airfoils

2021 ◽  
Vol 26 (2) ◽  
pp. 34
Author(s):  
Isaac Gibert Martínez ◽  
Frederico Afonso ◽  
Simão Rodrigues ◽  
Fernando Lau
Keyword(s):  
Topology Optimization ◽  
Shape Optimization ◽  
Volume Fraction ◽  
Optimization Techniques ◽  
Free Form ◽  
Aerodynamic Shape Optimization ◽  
Sequential Approach ◽  
Airfoil Surface ◽  
Aerodynamic Shape ◽  
Design Variables

The objective of this work is to study the coupling of two efficient optimization techniques, Aerodynamic Shape Optimization (ASO) and Topology Optimization (TO), in 2D airfoils. To achieve such goal two open-source codes, SU2 and Calculix, are employed for ASO and TO, respectively, using the Sequential Least SQuares Programming (SLSQP) and the Bi-directional Evolutionary Structural Optimization (BESO) algorithms; the latter is well-known for allowing the addition of material in the TO which constitutes, as far as our knowledge, a novelty for this kind of application. These codes are linked by means of a script capable of reading the geometry and pressure distribution obtained from the ASO and defining the boundary conditions to be applied in the TO. The Free-Form Deformation technique is chosen for the definition of the design variables to be used in the ASO, while the densities of the inner elements are defined as design variables of the TO. As a test case, a widely used benchmark transonic airfoil, the RAE2822, is chosen here with an internal geometric constraint to simulate the wing-box of a transonic wing. First, the two optimization procedures are tested separately to gain insight and then are run in a sequential way for two test cases with available experimental data: (i) Mach 0.729 at α=2.31°; and (ii) Mach 0.730 at α=2.79°. In the ASO problem, the lift is fixed and the drag is minimized; while in the TO problem, compliance minimization is set as the objective for a prescribed volume fraction. Improvements in both aerodynamic and structural performance are found, as expected: the ASO reduced the total pressure on the airfoil surface in order to minimize drag, which resulted in lower stress values experienced by the structure.

Price structures for electricity supply and potential consequences for building services systems

2021 ◽  
pp. 014362442199081
Author(s):  
Roger Hitchin
Keyword(s):  
Cost Effective ◽  
Building Design ◽  
Electricity Supply ◽  
Cooling Systems ◽  
Price Structure ◽  
Heating And Cooling ◽  
Future System ◽  
The Cost ◽  
Supply Systems ◽  
Effective Design

Policies to reduce carbon emissions are leading to substantial changes in the demand for electricity and to the structure of electricity supply systems, which will alter the cost structure of electricity supply. This can be expected to result in corresponding changes to the price structure faced by customers. This note is an initial exploration of how possible new price structures may impact on HVAC system and building design and use. Changes in the price structure of electricity supply (separately from changes in price levels) can significantly affect the cost-effective design and operation of building services systems; especially of heating and cooling systems. The nature and implications of these changes can have important implications for future system design and operation.

Probabilistic finite element analysis in heat transfer to a nuclear fuel rod bumper support

2004 ◽  
Vol 218 (12) ◽  
pp. 1499-1505
Author(s):  
Rama Subba Reddy Gorla
Keyword(s):  
Heat Transfer ◽  
Finite Element ◽  
Nuclear Fuel ◽  
Cost Effective ◽  
Distribution Functions ◽  
Cumulative Distribution ◽  
Element Analysis ◽  
Transfer Rates ◽  
Fuel Rod ◽  
Design Variables

Heat transfer from a nuclear fuel rod bumper support was computationally simulated by a finite element method and probabilistically evaluated in view of the several uncertainties in the performance parameters. Cumulative distribution functions and sensitivity factors were computed for overall heat transfer rates due to the thermodynamic random variables. These results can be used to identify quickly the most critical design variables in order to optimize the design and to make it cost effective. The analysis leads to the selection of the appropriate measurements to be used in heat transfer and to the identification of both the most critical measurements and the parameters.

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