Topology Optimization Software Research Articles

Level-set topology optimization of heat sinks with phase-change material

Phase-change materials (PCMs) excel in storing significant thermal energy through the latent heat of fusion during phase changes. However, they often suffer from low thermal conductivity, requiring the incorporation of materials with higher thermal conductivity to overcome this limitation. In this study, we employ the level-set method to topologically optimize the distribution of both PCM and high thermal conductivity materials within heat sinks.The heat transfer process is modeled as an unsteady diffusion problem, with PCM integrated using the apparent heat capacity method. The finite element method, implemented using FEniCS, is utilized to compute the temperature distribution at each time step. The optimization problem is solved using ParaLeSTO, a modular topology optimization software written in C++, seamlessly interfacing with FEniCS through its Python interface.To compute boundary point sensitivities for level-set topology optimization, the discrete adjoint method is employed, combining a perturbation scheme with automatic differentiation. The proposed methodology is first applied to a two-dimensional example of temperature oscillation minimization with a heat flux boundary condition, drawn from existing literature. Subsequently, a two-dimensional example with multiple volumetric heat sources is studied, followed by an extension to a three-dimensional design domain.Comparisons with optimized designs without PCM, serving as a reference, highlight the superior thermal performance of heat sink designs with PCM. The results showcase a maximum temperature reduction of up to 42%, a mean temperature reduction of up to 42%, and a temperature variance reduction of up to 94%. This research contributes to heat sink design by offering discrete solutions that significantly improve thermal performance as compared to designs without PCM. Its impact extends to addressing crucial challenges in thermal management across various applications, including automotive cooling systems, aerospace components, and consumer electronics.

Billion-design-variable-scale topology optimization of vehicle frame structure in multiple-load case

In topology optimization, sufficient resolution and a constraint volume of less than 1% are required to obtain a practical vehicle body structure without solid circular-section frames. To meet the requirement for sufficient resolution, the authors are developing voxel topology optimization software, including a finite element solver that utilizes the building cube method framework available in massively parallel environments. The authors have performed a topology optimization of billions of elements intended for a vehicle frame using 35,000–66,000 processors and measured its parallel performance. In addition, four different methods to treat multiple-load cases required for vehicle performance into single objective functions are examined. As a result, normalizing compliance with the appropriate target energy obtained by the original body-in-white frame balances the optimization performance across cases. In the single-load case, thick solid beams are generated through optimization. In contrast, such solid frames are suppressed in multiple-load cases, resulting in a structure similar to a practical body-in-white frame.

An Evolutive-Deformation approach to enhance self-supporting areas in Additive Manufacturing designs

Additive Manufacturing (AM) technology has matured rapidly in recent years, opening an engineering design freedom front when combined with Topology Optimization (TO). Although there is no doubt about their potential to provide optimal parts, there still exists a wide gap between them which reduces the efficiency of the design process. Overhang constraints in TO are still limited, therefore the designs generated by these algorithms are not yet ready for being directly manufactured. They usually need support structures to avoid droops or warps, which is time-consuming, costly and can lead to the loss of the optimal path since designers are required to manually redesign the geometry. The proposed approach combines both design and AM constraints into an automatic workflow in which the geometry provided by the TO software is evolved to minimize support structures for any printing direction while preserving its structural performance. The NSGA-II algorithm is coupled with a Free-Form Deformation (FFD) method to develop different geometries, while fitness is evaluated with FEM analysis. The framework provides Pareto Fronts with the most promising printing directions and geometries in terms of support structures, stiffness and weight. This multi-objective optimization approach that aims to improve TO parts manufacturability is applied to two case studies and one real-world part, highlighting on average a reduction of support structures of around 30%, whereas mass is practically preserved and stiffness decreased by 5%.

Avoiding reinventing the wheel: reusable open-source topology optimization software

Avoiding reinventing the wheel: reusable open-source topology optimization software

Topology Optimization Design of Biology Wooden Furniture

Reducting weight and exploring new structure, is an important issue that should be addressed as prerequisite in the design of furniture structure prior to the practical application of the Additive Manufacturing in furniture manufacturing. For the weight reduction and optimal material distribution with specific requirements on external loads and appropriate constraints, the topology optimization methods is most widely used. In this paper, by using Solid Thinking Inspire topology optimization software via simulation in terms of effective load and reasonable constraints on the 3D model of the chair, six different chair concept structure prototypes are obtained, which are then used to deepen the product scheme and to facilitate the Additive Manufacturing. Optimal topology optimization results are associated with the loads and constraints that applied. The actual use of the furniture should be also considered when apply topology optimization in designing furniture covering the load and constraints. Study results indicate that the topology optimization is an effective way to innovative furniture structure and design methods, which then provide new ideas for the development of new products. Besides, applying the correct external loads and constraints is the key for the optimal topology design, and is also the challenges for studies.

Application of a modular topology optimization framework to an aerospace bracket design

Abstract In aerospace industry, optimizing designs has become inevitable in terms of weight and performance requirements. Topology optimization is the most suitable optimization type for use in the conceptual design phase. Even though academic topology optimization algorithms have a modular structure (open to development), they are often useable for a regular design domain. Alternatively, commercial topology optimization software products, on the other hand, are very useful in terms of their solution speed, accuracy, and ability to handle complex or irregular design domains. However, the user is restricted with the optimization algorithms available in the software, and these software do not usually have a modular structure. In this study, a modular topology optimization framework that combines useful features of the academic codes (e.g., modularity) and the commercial software tools (e.g., capability of easily handling complex design domains) is developed. The developed framework is tested on two popular academic topology optimization problems, followed by aerospace bracket design problem. It is observed that the proposed framework usually provides lower objective function values and converges to the optimum result in fewer iterations than the Altair Optistruct topology optimization software.

A Comparative Study of the Application of Different Commercial Software for Topology Optimization

Topology optimization (TO) has been a popular design method among CAD designers in the last decades. This method optimizes the given design domain by minimizing/maximizing one or more objective functions, such as the structure’s stiffness, and at the same time, respecting the given constraints like the volume or the weight reduction. For this reason, the companies providing the commercial CAD/FEM platforms have taken this design trend into account and, thus, have included TO in their products over the last years. However, it is not clear which features, algorithms, or, in other words, possibilities the CAD designers do have using these software platforms. A comparative study among the most applied topology optimization software was conducted for this research paper. First, the authors developed an online database of the identified TO software in the form of a table. Interested CAD designers can access and edit its content, contributing in this way to the creation of an updated library of the available TO software. In addition, a deeper comparison among three commercial software platforms—SolidWorks, ANSYS Mechanical, and ABAQUS—was implemented using three common case studies—(1) a bell crank lever, (2) a pillow bracket, and (3) a small bridge. These models were designed, optimized, and validated numerically, as well as compared for their strength. Finally, the above software was evaluated with respect to optimization time, optimized designs, and TO possibilities and features.

Combining Macro- and Mesoscale Optimization: A Case Study of the General Electric Jet Engine Bracket

Topology optimization (TO) is a mathematical method that optimizes the material layout in a pre-defined design domain. Its theoretical background is widely known for macro-, meso-, and microscale levels of a structure. The macroscale TO is now available in the majority of commercial TO software, while only a few software packages offer a mesoscale TO with the design and optimization of lattice structures. However, they still lack a practical simultaneous macro–mesoscale TO. It is not clear to the designers how they can combine and apply TO at different levels. In this paper, a two-scale TO is conducted using the homogenization theory at both the macro- and mesoscale structural levels. In this way, the benefits of the existence and optimization of mesoscale structures were researched. For this reason, as a case study, a commercial example of the known jet engine bracket from General Electric (GE bracket) was used. Different optimization workflows were implemented in order to develop alternative design concepts of the same mass. The design concepts were compared with respect to their weight, strength, and simulation time for the given load cases. In addition, the lightest design concept among them was identified.

Re-engineering of Cast Product by Topology Optimization

Topology optimization is useful to carrying out the weight reduction and in process cost reduction can be achieved. This kind of optimization input shape and size modification and optimization give us improved product in reduction of material. For this study, planet pinion carrier is selected for topology optimization. Software gives an innovative real-time picture of company activities and ecosystem and links people, ideas and data in a single collaborative environment. The 3DEXPERIENCE platform as an operating system helps companies to achieve operational excellence. Casting is a process where allowances and other things are provided and if we could able to optimize the material and weight of the casting there is a scope for optimization the material size and shape in casting process. Planet pinion carrier which is a cast product is taken from well-known industry for topology optimization. For optimization that product first 3D model is done and this 3D model is given as an input for topology optimization software. Force analysis is carried out by using ANSYS software and then topology optimization procedure is applied accordingly product is optimized. After topology optimization again force analysis is carried out. It has been found that 20 percent reduction is observed in this study. The part details and load conditions are given by well-known industry for topology optimization. Size, shape and cost is reduced by giving various load conditions in FUSION 360 software. Modeling and remodeling is done using software. Comparative study has been done using AUTOCAST software. Part details are calculated and also casting flow and real time for actual casting is simulated by using software.

Robust topology optimization under loading uncertainties via stochastic reduced order models

AbstractAn efficient approach for topology optimization under uncertainty is presented. Stochastic reduced order models (SROMs) are leveraged for the modeling and propagation of uncertainties within a robust topology optimization (RTO) formulation. The SROM approach provides an alternative to existing uncertainty quantification methods and yields a substantial improvement in efficiency over a classical Monte Carlo based approach while retaining similar accuracy when representing the uncertainty in system parameters. In particular, random input parameters can be discrete or continuous and specified either analytically (standard distributions) or numerically (dataset samples). Furthermore, multiple random quantities need not be treated as uncorrelated; an SROM can seamlessly model random vectors with arbitrary correlation structure. The nonintrusive nature of the SROM method yields an implementation that can be seen as a drop‐in replacement for a simple RTO approach that leverages Monte Carlo simulation and is therefore straightforward to implement in existing topology optimization software. The proposed approach is demonstrated in the context of structural topology optimization with uncertainty in applied loads. Several numerical results are presented, covering a range of uncertainty distributions that illustrate the flexibility afforded by the general SROM method, while highlighting the efficiency and accuracy achieved in uncertainty propagation.

Structural design of a morphing serpentine inlet using a multi-material topology optimization methodology

A promising avenue for development in the aerospace industry involves relocation of engines from conventional locations beneath the wings, to within the aircraft fuselage. Aircraft with these so-called embedded engines have the potential to increase engine efficiency, but necessitate the use of a serpentine engine inlet duct (S-duct) to provide the propulsion system with air. The optimal shape of an aircraft S-duct varies with flight condition, incentivizing the use of morphing systems to vary inlet parameters during flight: allowing for continual supply of the optimal airflow level. Design of a morphing system therefore requires collaboration across multiple disciplines, including aerodynamic analysis and structural analysis. This work presents a methodology for the structural optimization of morphing systems utilizing aerodynamic shape optimization results as inputs, in order to assess the relationship between morphing performance and structural stiffness. The methodology is implemented on a baseline morphing S-duct model for which shape optimization has been previously conducted. Structural optimization is conducted using a gradient-based multi-material topology optimization software with multi-phase penalization. While the conclusions of this work indicate that the impact of multiple material optimization in the S-duct case study is minimal, the methodology does provide non-intuitive designs capable of supporting morphing. At the expense of structural stiffness, the methodology is shown to increase morphing performance through the generation of compliant mechanisms. A parameter study conducted on the S-duct model successfully proves the ability of the methodology to assess the trade-offs between structural and morphing performance. By emphasizing morphing performance, mass reductions from 1.75 kg to 0.201 kg were observed at the expense of a 94% reduction in fatigue lifecycle.

Topology optimization and additive manufacturing in producing lightweight and low vibration gear body

Reducing gear vibration as well as its weight is a challenging field latterly. This research deals with the manufacturing of a gear having cellular lattice body structure by using Selective Laser Melting (SLM) technology. A cellular lattice design defines a complex structure which typically cannot be fabricated by conventional manufacturing technologies. On the other hand, the SLM technology enables the production of such complex cellular lattice structures directly from their computer-aided designed (CAD) models. The cellular gear body structure was designed and optimized by employing topology optimization software ProTOp and fabricated by SLM using Ti-6Al-4V alloy. The problems faced by the researchers and the solution which enabled the manufacturing of this gear by SLM are described in this paper. To estimate the performance of the gear during operation, the sound pressure was measured and compared to the results obtained with the gear having a solid body. The experimental results show that the investigated cellular lattice structure of the gear body is well capable to reduce the mass and vibration of the gear.

Use of 3D printing in production of personal protective equipment (PPE) - a review

The use of personal protective equipment (PPE) is vital in the field of construction, medicine, military, firefighting etc., The design and manufacturing capabilities of such equipment are limited using traditional manufacturing processes. Developments in generative design, topology optimization, light weighting and latticing software, and new additive manufacturing processes has increased the robustness and quickness to manufacture PPE, s with exceptional design freedom and superior performance. In today’s world where corona virus is creating a huge problem to everyone, the industrial sector is down all across the globe as most industries are working on 30% of overall workers, a process like 3D printing is the right way to still keep the production level high. In 3D printing one only needs to feed the machine the design that you want to make, and the machine prints that model using plastic or metal material. This can be especially useful as there is no contact between the workers and can be done easily. The design can be made while sitting at home and the model after printing can be taken out by a single worker, thus allowing the industry to work at 30% of its workforce. Currently there is a huge requirement of personal protective equipment as they can be proved as the line between life and death. This review paper discusses the capabilities of 3D printing in making protective equipment such as helmets, protective masks, prosthesis, knee braces, goggles, test swabs, fire fighting gears and earplugs.

Novel implementation of extrusion constraint in topology optimization by Helmholtz-type anisotropic filter

In this paper, a novel implementation of extrusion constraint in topology optimization is proposed based on Helmholtz-type anisotropic filter approach. The main idea is to set a far larger filter feature size along the extrusion direction than other directions, and thus, the density field is kept constant along the extrusion direction. The Helmholtz-type anisotropic filter can be easily implemented by adding a few more parameters to the isotropic one. Three illustrative examples, including 3D cantilever, spherical frame, and S-shape curved shell, are carried out to verify the effectiveness and robustness of the proposed method. Example results corroborate that the proposed method is suitable for both regular and irregular meshes regardless of geometrical complexity. Compared with the traditional variable mapping method, the proposed method needs less manual setup in the preprocessing of the analysis model for implementing extrusion constraint in topology optimization, which can be easily integrated into the solid isotropic materials with penalization (SIMP) topology optimization or commercial topology optimization software.

REDESIGN AND TOPOLOGY OPTIMIZATION OF AN INDUSTRIAL ROBOT LINK FOR ADDITIVE MANUFACTURING

Design optimization for Additive Manufacturing is demonstrated by the example of an industrial robot link. The part is first redesigned so that its shape details are compatible with the requirements of the Selective Laser Sintering technique. Subsequently, the SIMP method of topology optimization is utilized on commercially available software in order to obtain the optimum design of the part with restrictions applicable to Additive Manufacturing, namely member thickness, symmetry and avoidance of cavities and undercuts. Mass and strain energy are the design responses. The volume was constrained by a fraction of the initial mass. The desired minimization of maximum strain energy is expressed as an objective function. A 7% reduction in the mass of the part was achieved while its strength and stiffness remained unchanged. The process is supported by topology optimization software but it also involves some trial-and-error depending on the designer’s experience.

Topology optimization through stiffness/weight ratio analysis for a three-point bending test of additive manufactured parts

Topology Optimization (TO) is a technique that allows for increasingly efficient designs and its objective is to maximize the performance of mechanical systems or structure in a variety of fields. Attempts to employ TO for parts manufactured with conventional methods such as casting, forging, injection moulding, CNC machining and the like could not lead to desired optimum results due to the existing manufacturing constraints regarding geometrical complexity. Currently, additive manufacturing (AM) techniques allow the fabrication of more complex shapes which in principle will lead to improved performances through application of the TO concept. This study focuses on structural optimization of additive manufactured parts of thermoplastic parts based on analysis of the stiffness/weight (mass) ratio for a beam subjected to a three-point bending load. The experimental work is done on optimization of parts manufactured by Fused Deposition Modelling (FDM) technology and finally compared with an identical model manufactured using Polyjet 3D printer. Different TO software are compared to conduct the optimization, and a module of SolidWorks 2018 from Dassault Systems is chosen for the topology optimization for the final experiment. The study focuses on the results on stiffness/mass ratios, paying attention to the influence of different printing parameters on the test results. An increase of stiffness/weight ratio of 31.7% was predicted by software while experiments showed an increase of just 27.04%.

Multiscale topology optimization using atomic finite element method (AFEM)

In this research, the applicability of Atomic Finite Elements to topology optimization is analyzed. To do this, a structural atomic simulation based on the AFEM is developed and analyzed, and then used to implement a molecular level topology optimization software.

Design Methodology for Topology Optimization of Dynamically Loaded Structure

This paper investigates the application of topology optimization to a complexly loaded structure. Specifically, a time-dependent impact scenario is considered for conversion using a weighted compliance method and input into the topology optimization software, OptiStruct. The weights on the weighted compliance are varied using a modified extensible lattice sequence to understand any overlap in load steps and their impact on the overall objective function.

An algorithm for topology optimization of gear reducer housing elements

In recent years, topology optimization methods are becoming more widely used in many engineering fields, and they are already being successfully integrated at the design stage of the different types of products. An active field of research in this area is the definition of appropriate constraints in topology optimization models in order to facilitate the production of the optimized objects. An algorithm for topology optimization of housing elements from gear reducers by using the capabilities of CAD-CAE topology optimization software is presented in the current work. The purposed algorithm is taking into account the resulting loads during operation of the reducer, the geometrical and manufacturing constraints of the production process of these housing elements. Obtained results from conducted Taguchi experimental study to investigate the impact of some topology optimization control parameters over optimized 3D-model also are shown and discussed. Conclusions on the applicability of the algorithm have been made.

Characterization of topology optimized Ti-6Al-4V components using electron beam powder bed fusion

The use of manufacturing to generate topology optimized components shows promise for designers. However, designers who assume that additive manufacturing follows traditional manufacturing techniques may be misled due to the nuances in specific techniques. Since commercial topology optimization software tools are neither designed to consider orientation of the parts nor large variations in properties, the goal of this research is to evaluate the limitations of an existing commercial topology optimization software (i.e. Inspire®) using electron beam powder bed fusion (i.e. Arcam®) to produce optimized Ti-6Al-4V alloy components. Emerging qualification tools from Oak Ridge National Laboratory including in-situ near-infrared imaging and log file data analysis were used to rationalize the final performance of components. While the weight savings of each optimized part exceeded the initial criteria, the failure loads and locations proved instrumental in providing insight to additive manufacturing with topology optimization. This research has shown the need for a comprehensive understanding of correlations between geometry, additive manufacturing processing conditions, defect generation, and microstructure for characterization of complex components such as those designed by topology optimization.