Level set-based topological design of multiphase micro-architectured materials using alternating active-phase method

Abstract

Micro-architectured materials with periodically configured microstructures are widely used in various engineering fields due to their superior mechanical properties. Compared with conventional topology design with one single material, topological design with multiple materials can provide a better solution as the expanded design freedom. This paper presents a level set-based multi-material topological design method for micro-architectured materials involving three phases or more. In this method, a difference-set-based multi-material level set model is employed to represent the topology of each phase, in which N + 1 phases can be precisely represented by the sequential difference-set of N level set functions without any overlaps and redundant regions. By using an alternating active-phase algorithm, the multi-material topology design problem with N + 1 phases is splitted into N(N + 1)/2 binary-phase topological design sub-problems, where each sub-problem involves fewer design variables and volume constraints. The effective properties of multiphase micro-architectured materials are evaluated by a numerical homogenization approach, and their topological evolutions of two active phases in each sub-problem can be readily achieved by updating a single level set function, which greatly facilitate the extension to topological design problems with more phases. Both numerical examples and additive-manufactured specimens demonstrate the effectiveness of the proposed method for designing multiphase micro-architectured materials.