Structural Design Optimization Research Articles

Study on the Energy Absorption Characteristics of Different Composite Honeycomb Sandwich Structures under Impact Energy

A honeycomb structure is a sandwich structure widely used in fuselage, among which the hexagonal honeycomb core is the most widely used. The energy absorption characteristics and impedance ability of the structure are the main reasons that directly affect the energy absorption characteristics of the honeycomb sandwich structure. Therefore, it is necessary to study the out-of-plane mechanical properties of the composite honeycomb sandwich structure. Based on the numerical simulation results, the energy absorption characteristics of several composite honeycomb sandwich structures are verified by drop hammer impact experiments. The research shows that the transient energy absorption characteristics of the composite honeycomb sandwich structure are mainly related to the cell size of the honeycomb structure. The smaller the size of the front cell, the stronger the overall impact resistance; the strength of the composite honeycomb sandwich structure exceeds that of 7075 aluminum alloy-NOMEX and carbon fiber-NOMEX honeycomb sandwich structures. In this paper, the energy absorption characteristics of composite honeycomb sandwich structures under different impact energy are compared and studied. The displacement, force and energy curves of energy absorption characteristics related to time variables are analyzed. The difference in protective performance between the composite honeycomb sandwich structure and existing airframe structure is compared and studied. The optimal structural design parameters of composite honeycomb sandwich under low-speed impact of drop hammer are obtained. The maximum energy absorption per unit volume of the designed honeycomb sandwich structure is 171.7% and 229.8% higher than that of the NOMEX-AL and NOMEX-C structures. The 6.4 mm and 3 mm cell sizes show good characteristics in high-speed buffering and crashworthiness. The composite honeycomb sandwich airframe structure can improve the anti-damage performance of the UAV airframe structure, ensure the same thickness and lightweight conditions as the existing honeycomb sandwich airframe structure, and improve the single-core bearing mode of the existing airframe structure.

Transformational green sustainable concepts in the field of infrastructure

In this comprehensive study, we explore the multifaceted world of green sustainable construction, highlighting innovative techniques and materials. This article presents an insightful exploration of green sustainable construction, focusing on the crucial aspects of architectural design, judicious material selection, and the adoption of optimal structural designs. Through comprehensive literature research supplemented by practical examples, it highlights several innovative construction methodologies that are at the forefront of green sustainable development. These include the use of lightweight framing, cladding systems, autoclaved aerated concrete (AAC), rammed earth, and straw bale construction, each contributing uniquely to environmental sustainability. The study brings to light the looming issue of raw material scarcity due to excessive exploitation, urging for sustainable material management in construction. It stresses the urgency of implementing effective pollution control measures within the construction sector, asserting that such practices are not just beneficial but essential for environmental conservation and sustainable development. This research contributes significantly to the field by providing a foundation for future exploration and advancements in sustainable construction practices.

Structural optimization design of connection between centrifugal impeller and shaft end based on finite element method

A centrifugal compressor is the core equipment of the chemical industry. To solve the problems of assembly difficulties and poor mechanical properties caused by the connection between impeller and shaft end in existing compressor, this paper takes a small geared air compressor designed by Shenyang Borui Turbine Technical Service Co., Ltd. as an example and designs its first-stage impeller and shaft end into three structural forms of tie rod–pin connection, tie rod–end key connection, and flange connection, respectively, to find an optimal connection mode between the centrifugal impeller and shaft end. Firstly, the calculation method is verified. Then, the stress, strain, deformation, and critical rotor speed of these three structures are compared and analyzed based on multi-parameter genetic optimization method. The results show that when the impeller and shaft end are connected by the tie rod–end key structure, compared to the tie rod–pin connection structure and flange connection structure, the maximum stress is reduced by 43.8% and 61.2%, the strain is reduced by 43.8% and 61.8%, the deformation is reduced by 3.64 times and 6.27 times, respectively, and the resonance margin will also be greatly improved. The research results in this paper provide a theoretical basis for the reliable design of the connection between the centrifugal impeller and shaft end.

Gaussian cross-entropy and organizing intelligence for design optimization of the outrigger system with inclined belt truss in real-size tall buildings

This research explores the optimal structural design for tall buildings with an outrigger and belt truss system. The study employs Gaussian Cross-Entropy with Organizing Intelligence (GCE-OI), a novel optimization approach that utilizes a self-organizing map as a machine learning algorithm, and Gaussian probability distribution in Cross-Entropy optimization. This approach is used to predict promising solutions and to guide the search process for swift convergence. The optimization encompasses member sizing (weight) and outrigger placement (topology) while introducing inclined belt trusses alongside traditional horizontal trusses for enhanced performance. The process involves optimizing a 25-story real-size model subjected to wind load, and the results are compared against multiple well-known algorithms. The results show that the proposed optimizer, supported by machine learning, outperforms alternative algorithms, offering superior solutions with enhanced convergence. Considering the efficiency of the inclined belt trusses and the proposed robust optimization method (GCE-OI), the optimally-placed outrigger system minimizes the constructional cost and enhances structural stability by limiting the responses.

Structural optimization design of ice abrasive water jet nozzle based on multi-objective algorithm

To enhance the cleaning efficiency of the ice abrasive water jet (IAWJ), the nozzle in the jet structure was optimized. The cleaning effect of nozzle with different structural design is different. The design variables include the geometric parameters of the nozzle's structure and the flow process parameters of the jet. The maximum wall static pressure, outlet velocity and wash width are the optimization objectives. Based on the Optimal Latin Hypercube Sampling (OLHS) method, 50 sets of sample capacity were designed for simulation calculation. The parameter functions associated with the three objectives were fitted by MATLAB. The Competitive mechanism multi-objective particle swarm optimizer (CMOPSO) algorithm was used to optimize the nozzle to improve the cleaning effect, which was verified with the test results. The inlet pressure and outlet diameter are critical factors influencing the cleaning effect of the IAWJ. The maximum wall static pressure produced by the optimized nozzle is about 4.5% higher than that of the ordinary cosine nozzle. The cleaning effect of the optimized nozzle is 10% higher than that of the ordinary cosine nozzle, which is verified by the experiments. The optimization of the nozzle serves as a valuable reference for the nozzle structure design of the cleaning machine.

Multi-objective optimization design of power pack structures based on floating projection topology optimization

Battery packs are vital components for storing and releasing energy. However, during driving, the intensity of heat emission and mechanical performance of electric vehicles are interrelated but conflicting indicators. To address this problem, this study topologically optimizes the power pack support structure with multiple objectives of minimizing compliance and heat dissipation, aiming to achieve a comprehensive and integrated design scheme. A floating projection topology optimization (FPTO) method is proposed, which normalizes the objectives of structural compliance and heat dissipation and derives the sensitivity. FPTO demonstrates superior objective function values and smoother topology configuration compared to the solid isotropic material with penalization (SIMP) method. Finally, the proposed method is applied to the power pack support structure. The results demonstrate that the method obtains a design solution with excellent mechanical performance and high heat dissipation performance with a suitable trade-off. The lightweight design of the overall structure of the battery pack is achieved.

Performance analysis of electrical signal output of multi-state flexoelectric structures with parameter uncertainties through quasi-Monte Carlo method

Flexoelectric effect is a more universal electromechanical coupling effect than piezoelectric effect. Flexoelectric beams as the main structural component of flexoelectric power signal output have broad application prospects in the next generation of micro–nano electromechanical systems. However, the electrical signal output of flexoelectric structures in macro-scale is far less than the output of the piezoelectric signal. Therefore, it is urgent to explore the influence of the parameter uncertainties on the electrical signal output of the flexoelectric structures, in order to improve the electrical signal output of flexoelectric materials with excellent design performance. Based on the quasi-static theory, the output voltage model and the output charge model of flexoelectric structures as well as the effective piezoelectric coefficient model are constructed. Then the influences of the flexoelectric parameters on the output voltage and the output charge are researched as well as the influence of the effective piezoelectric coefficient. Finally, the influences of uncertain parameters under different electrical states (e.g. the electrical open circuit and short circuit states) on the output performance of flexoelectric signal are studied by the quasi-Monte Carlo method, in order to further provide a reference for the reliability analysis and optimization design of the flexoelectric structures.

Dynamic response optimization of the multistage sandwich structures imperiled to explosive loading

Explosive attacks are increasing day by day in the present era, and the design optimization of protective structures without increasing their weight is mainly a critical task for vehicles. Assessment of the dynamic response of the structures under explosive loading through experimentation is costly, with many restrictions, and highly harmful for both people and the environment. Hence, the present study deals with an explicit numerical investigation of the protective sandwich structures’ blast performance. The influence of the number of stages of honeycomb on the sandwich structures’ blast mitigation capacity was evaluated with the effective utilization of face sheets’ material as their intermediate sheets while maintaining the total volumes as well as masses of the structure's constant. The explosive loads of 1 to 3 kg of trinitrotoluene were used for the stand-off distance of 100 mm. The rate-dependent Johnson-Cook plasticity model was implemented on the designed sandwich models to discover their damage behaviors. The sandwiches’ face deflection, energy absorption, kinetic energy variation, and crushing behaviors were considered to characterize their blast mitigation capacity. The obtained results showed that increasing the number of stages of core in the sandwich structure by using a fraction of the back face sheet materials for intermediate sheets significantly improved their blast performance without increasing their volume occupancies and masses. For the two-stage and three-stage sandwich designs, 50% and 20%, respectively, utilization of their back face material for their intermediate sheet was found to be optimal.

Structural analysis and optimal design of a spherical thin-walled stainless steel water tank without reinforced tie ribs

A spherical thin-walled stainless steel water tank without reinforced tie ribs has been designed to address the issues of easy fracture and corrosion of the ribs, difficulty in maintenance and cleaning, and short service life exposed during the use of thin-walled stainless steel water tanks with reinforced tie ribs. Firstly, an analytical model of a flat steel thin-walled water tank without reinforced tie ribs was established and subjected to static analysis under water pressure. The deformation and stress distribution patterns of the side molded plate of the flat box were obtained. Secondly, a spherical non ribbed thin-walled stainless steel water tank structure was designed with circular cross-section under different box bulge parameters, and its mechanical response characteristics under water pressure load were analyzed. A strengthening scheme was designed for the bottom box molded plate. Once again, optimize the combination design of the box scheme and the reinforcement scheme, and analyze their static, thermodynamic, and thermal solid coupling performance. Finally, the Latin Hypercube Sampling method was used to generate experimental design samples, and a response surface approximation model of a spherical thin-walled stainless steel water tank without reinforced tie ribs was constructed. The wall thickness of the box molded plate, skeleton, and reinforcement were used as design variables, and the maximum deformation and maximum equivalent stress were used as constraints. The lightweight design was carried out with the goal of minimizing mass. The research results indicate that the design program and parameter selection method for spherical thin-walled stainless steel water tanks without reinforced tie ribs proposed in the article are efficient and feasible, and can provide technical reference and theoretical support for the layout and overall optimization design of non ribbed thin-walled stainless steel water tank structures.

Optimal design of truss domes with frequency constraints using seven metaheuristic algorithms incorporating a comprehensive statistical assessment

In this article, seven recently developed metaheuristic algorithms are utilized for optimal design of dome-shaped trusses with natural frequency constraints. These algorithms are social network search, jellyfish search optimizer, equilibrium optimizer, teaching-learning-based optimization, grey wolf optimizer, colliding bodies optimization, and the improved grey wolf optimizer. This study focuses on the assessment and tuning of these algorithms to enhance both computational efficiency and solution quality. In particular, we introduce a hyperparameter tuning procedure that significantly improves the performance of the algorithms to make them more suitable for the solution of structural optimization problems. The performance of the selected algorithms is studied through five benchmark examples for design optimization of dome structures, from small-scale to large-scale cases, with frequency constraints. Many combination scenarios are studied for hyperparameter tuning of the algorithms in each design example in order to provide comprehensive statistical results determining the sufficient number of structural analyses as well as the number of particles to find an efficient condition of each algorithm. Indeed, this study also presents an insight into the efficient setting of hyperparameters for each algorithm, leading to a better solution with lower computational cost. Furthermore, the optimization results provide a comparison of the solutions obtained in the current and previous studies in order to demonstrate the suitability of the selected algorithms.

Failure analysis and numerical drive structure optimization design of Cr12Mo1V1 electrical connection die

A type of Cr12Mo1V1 electric connection die occured brittle fracture after 200 times of service, and its life was much lower than the design life of the die. In this paper, the 5M1E failure analysis method was adopted, combined with the characteristics of Cr12Mo1V1 cold-work die steel, scanning electron microscopy, direct reading spectrometer, Rockwell hardness tester, metallographic microscope and other means were used to analyze and test the macro fracture morphology, material composition, mechanical properties and microstructure of Cr12Mo1V1 electric connection die. The crimping process of the die was simulated by Deform software. The results show that the material composition is not up to standard, the strength is too low, the internal eutectic carbide is not uniform, the size of carbide exceeds the standard and so on are the root causes of the short life and brittle fracture of the die. In addition, the unreasonable designs of the crack slot and round hole of the die lead to excessive stress concentration in the crimping process of the die, which is too the main reason for the brittle fracture failure of the die. In view of the above factors, the paper puts forward some measures to prolong the life of the electric connection die from the aspects of raw materials, heat treatment, forging process and die structure design.

Numerical Analysis of Water–Sediment Flow Fields within the Intake Structure of Pumping Station under Different Hydraulic Conditions

The vortices, backflow, and siltation caused by sediment-laden flow are detrimental to the safe and efficient operation of pumping stations. To explore the effects of water–sediment two-phase flow on the velocity field, vorticity field, and sediment distribution within intake structures, field tests and numerical simulations were conducted in this study with consideration for the sediment concentration, flow rate, and start-up combination. We applied a non-contact laser scanner and ultrasonic Doppler velocimetry to obtain the field data and reverse modeling of the three-dimensional model of the intake structure under siltation. A multiphase flow model based on the Euler–Euler approach combined with the k-ε turbulence model was adopted for numerical simulation under 10 working conditions, and the reliability was verified with field data. The results indicate that sediment promotes the evolution of coaxial vortices into larger-scale spiral vortices along the water depth, and the process of sediment deposition is controlled by the range, intensity, and flow velocity of the backflow zone. Furthermore, the maximum volume fraction of the near-bottom sediment increased by 202.01% compared to the initial state. The increase in flow rate exacerbates the turbulence of the flow field. Although the increase in sediment concentration benefits the flow diffusion, it further promotes sediment deposition. This study provides a new idea for modeling complex surfaces and considers different operating conditions. It can serve as a scientific reference for the structural optimization and anti-siltation design of similar water-conservancy projects.

Review on structural optimization techniques for additively manufactured implantable medical devices

Recent developments in additive manufacturing (AM) have led to significant opportunities in the design and fabrication of implantable medical devices due to the advantages that AM offers compared to conventional manufacturing, such as high customizability, the ability to fabricate highly complex shapes, good dimensional accuracy, a clean build environment, and reduced material usage. The study of structural design optimization (SDO) involves techniques such as Topology Optimization (TO), Shape Optimization (SHO), and Size Optimization (SO) that determine specific parameters to achieve the best measurable performance in a defined design space under a given set of loads and constraints. Integration of SDO techniques with AM leads to utmost benefits in designing and fabricating optimized implantable medical devices with enhanced functional performance. Research and development of various lattice structures represents a powerful method for unleashing the full potential of additive manufacturing (AM) technologies in creating medical implants with improved surface roughness, biocompatibility, and mechanical properties. Furthermore, the integration of artificial intelligence (AI) and machine learning (ML) in structural optimization has expanded opportunities to improve device performance, adaptability, and durability. The review is meticulously divided into two main sections, reflecting the predictability of the implant’s internal structure: (a) unpredictable interior topology, which explores topology-based optimization techniques, and (b) predictable inner topology, concentrating on lattice structures. The analysis of the reviewed literature highlights a common focus on addressing issues such as stress shielding, osseointegration enhancement, customization to individual needs, programmable functionalities, and weight reduction in implant designs. It emphasizes significant advances in reducing stress shielding effects, promoting osseointegration, and facilitating personalized implant creation. The review provides a detailed classification of optimization methods, with each approach scrutinized for its unique contribution to overcoming specific challenges in medical implant design, thus leading to more advanced, effective, and patient-oriented implantable devices.

Augmented Space Integral Approach for Structural Reliability-Based Optimization

An efficient, fully decoupled approach is proposed to solve the structural reliability-based design optimization (RBDO) problem. The proposed approach utilizes augmented space integral and importance sampling (ASI-IS) to efficiently evaluate a functional relationship between the probability of failure and the design parameters, namely the so-called failure probability function. ASI-IS allows for the avoidance of both the intractable density fitting task associated with augmented space methods and the time-consuming repeated reliability evaluations associated with surrogate model approaches. The resulting functional relationship can be used to completely decouple the original RBDO problem into a deterministic one. Then, an iteration mechanism is constructed with gradually smaller design domains to enhance the efficiency of the optimization process. Furthermore, a sample reuse algorithm is proposed to improve the performance of the proposed approach by collecting the samples generated in previous iterations and reusing them in the current iteration in order to produce a better estimator of the failure probability function. Numerical and engineering examples, including a turbine blade and an aircraft inner flap, are given to demonstrate the efficiency and feasibility of the proposed approach.

A novel subset assignment and matching method for DIC measurement of complex deformation in aircraft braking process

This paper proposes a measurement method related to the braking deformation of a complex motion. During the braking process, the deformation of the wheel includes large amounts of movement, vibration, warping, and distortion. A novel subset assignment and correlation method is proposed to measure the complex deformation. The proposed method can greatly improve the accuracy and stability of the calculation of complex deformations by simplifying the complex deformation into translational deformations in logarithmic coordinate system. According to the simulation and actual experiments, the proposed method can be utilized to measure the deformations of up to 100% tensile strain under complex deformation. According to the accuracy verification experiment, the error of the proposed method is less than 50 με. The results show that the proposed method can effectively carry out structural deformation measurement in the complex motion and deformation process. The proposed method has great significance for structural performance analysis and optimization design considering complex motion and deformation.

Acoustic wave devices based on piezoelectric/ferroelectric thin films for high-frequency communication systems and sensing applications

Surface acoustic wave (SAW) and bulk acoustic wave (BAW) based radio-frequency (RF) filters dominate in handsets markets mainly because they have miniature size so multiple filters can be used but take up very small board area. Besides, due to their inherent advantages, such as low insertion loss, relatively high resonant frequency, and miniature size, their application in the physical and biochemical sensing fields has also gradually expanded. The successful implementation requires specific knowledge of acoustic wave properties, the working mechanisms, material properties, and device design. So, in this review, we survey the SAW and BAW filter technology by discussing the working principles and the comparison between the operation frequency band allocations. In addition, the approaches to enhance the performance including the selection of single crystal/ferroelectric materials for BAW and the structure design optimization for SAW are introduced with discussions for further improvement. Then, flexible SAW and BAW devices are also presented and their new application opportunities in the fields of skin-like electronics and wearable health monitoring devices can be foreseen. Finally, the potential challenges of high frequency, wide bandwidth, miniaturization, and compatibility with the integrated circuits (IC) manufacturing process are overviewed as well.

Multi-physical Field Analysis Method for Enclosed Isolated Phase Busbar of Hydropower Station

In this paper, geometrical modelling and finite element multi-physical field analysis method are carried out for the actual layout of the enclosed isolated phase busbar (EIPB) of a hydropower station, for the horizontal and vertical connection parts that can hardly be considered in the analytical calculation process. The finite element model is able to accurately represent the main structure of the EIPB by reasonably simplifying some of the components. Meanwhile, the finite element model incorporates the coupling of magnetic field and transient structural field, allowing for analysis of the magnetic field distribution, stress-strain distribution, modal analysis, and harmonic response of each component of the EIPB. It is capable of analyzing the vibration response of the complex horizontal-vertical structure EIPB under different excitations. This method can overcome the limitations of analytical calculation methods in calculating complex structure EIPBs. It can also provide valuable guidance for the structural optimization design of future EIPBs.

Hole cleaning evaluation and installation spacing optimization of cuttings bed remover in extended-reach drilling

In extended-reach or long-horizontal drilling, cuttings usually deposit at the bottom of the annulus. Once cuttings accumulate to a certain thickness, complex problems such as excessive torque and drag, tubing buckling, and pipe stuck probably occur, which results in a lot of non-productive time and remedial operations. Cuttings bed remover can efficiently destroy deposited cuttings in time through hydraulic and mechanical stirring effects. This paper aims to build a method for hole cleaning evaluation and installation spacing optimization of cuttings bed remover to improve the wellbore cleaning effect. Firstly, a Computational Fluid Dynamics approach with Eulerian–Eulerian multiphase model was utilized to investigate the mechanism of cuttings transportation, and a new type of cuttings bed remover was designed. Next, an evaluation method of hole cleaning effect of remover was established. After that, the effects of several drilling parameters on hole cleaning including flow rate of drilling fluid, rotational speed of drillpipe, rate of penetration, wellbore size, rheological property of drilling fluid, and remover eccentricity on the performance of cuttings bed remover were investigated. The results demonstrate that the new type of remover with streamline blade performs better than conventional removers. The efficiency of hole cleaning is greatly improved by increasing the rotational speed of drillpipe, flow rate of drilling fluid, remover eccentricity, and 6 rpm Fann dial reading for drilling fluid. While higher rate of penetration and large wellbore size result in worse hole cleaning. These findings can serve as an important guide for the structure optimization design of cuttings bed remover and installation spacing of removers.

Design and Study of Machine Tools for the Fly-Cutting of Ceramic-Copper Substrates.

Ceramic-copper substrates, as high-power, load-bearing components, are widely used in new energy vehicles, electric locomotives, high-energy lasers, integrated circuits, and other fields. The service length will depend on the substrate's copper-coated surface quality, which frequently achieved by utilising an abrasive strip polishing procedure on the substrate's copper-coated surface. Precision diamond fly-cutting processing machine tools were made because of the low processing accuracy and inability to match the production line's efficiency. An analysis of the fly-cutting machining principle and the structural makeup of the ceramic-copper substrate is the first step in creating a roughness prediction model based on a tool tip trajectory. This model demonstrates that a shift in the tool tip trajectory due to spindle runout error directly impacts the machined surface's roughness. The device's structural optimisation design is derived from the above analyses and implemented using finite element software. Modal and harmonic response analysis validated the machine's gantry symmetrical structural layout, a parametric variable optimisation design optimised the machine tool's overall dimensions, and simulation validated the fly-cutterring's constituent parts. Enhancing the machine tool's stability and motion accuracy requires using the LK-G5000 laser sensor to measure the guideway's straightness. The result verified the machine tool's design index, with the Z- and Y-axes' straightness being better than 2.42 μm/800 mm and 2.32 μm/200 mm, respectively. Ultimately, the device's machining accuracy was confirmed. Experiments with flying-cut machining on a 190 × 140 mm ceramic-copper substrate yielded a roughness of Sa9.058 nm. According to the experimental results, the developed machine tool can fulfil the design specifications.

Structure optimization design of extracorporeal circulation blood transport pump

Structure optimization design of extracorporeal circulation blood transport pump