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

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.

Preliminary Sailplane Design Using MDO And Multi-Fidelity Analysis

A multidisciplinary design optimization (MDO) strategy for the preliminary design of a sailplane has been developed. The proposed approach applies MDO techniques and multi-fidelity analysis methods which have seen successful use in many aerospace design applications. A customized genetic algorithm (GA) was developed to control the sailplane optimization that included aerodynamics/stability, structures/weights and balance and, performance/airworthiness disciplinary analysis modules. An adaptive meshing routine was developed to allow for accurate modeling of the aero structural couplinginvolved in wing design, which included a finite element method (FEM) structural solver along with a vortex lattice aerodynamics solver. Empirical equations were used to evaluate basic sailplane performance and airworthiness requirements. This research yielded an optimum design that correlated well with an existing high performance sailplane. The results of this thesis suggest that preliminary sailplane design is a well suited application for modern optimization techniques when coupled with, multi-fidelity analysis methods.

Preliminary Sailplane Design Using MDO And Multi-Fidelity Analysis

A multidisciplinary design optimization (MDO) strategy for the preliminary design of a sailplane has been developed. The proposed approach applies MDO techniques and multi-fidelity analysis methods which have seen successful use in many aerospace design applications. A customized genetic algorithm (GA) was developed to control the sailplane optimization that included aerodynamics/stability, structures/weights and balance and, performance/airworthiness disciplinary analysis modules. An adaptive meshing routine was developed to allow for accurate modeling of the aero structural couplinginvolved in wing design, which included a finite element method (FEM) structural solver along with a vortex lattice aerodynamics solver. Empirical equations were used to evaluate basic sailplane performance and airworthiness requirements. This research yielded an optimum design that correlated well with an existing high performance sailplane. The results of this thesis suggest that preliminary sailplane design is a well suited application for modern optimization techniques when coupled with, multi-fidelity analysis methods.

Performance Analysis of FEM Solvers on Practical Electromagnetic Problems

The paper presents a comparative analysis of different commercial and academic software. The comparison aims to examine how the integrated adaptive grid refinement methodologies can deal with challenging, electromagnetic-field related problems. For this comparison, two bench-mark problems were examined in the paper. The first example is a solution of an L-shape domain like test problem, which has a singularity at a certain point in the geometry. The second problem is an induction heated aluminum rod, which accurate solution needs to solve non-linear, coupled physical fields. The accurate solution of this problem requires applying adaptive mesh generation strategies or applying a very fine mesh in the electromagnetic domain, which can significantly increase the computational complexity. The results show that the fully-hp adaptive meshing strategies, which are integrated into Agros Suite, can significantly reduce the task's computational complexity compared to the automatic h-adaptivity, which is part of the examined, popular commercial solvers.