TFOS22 FEA and Optimization Driven Design

Assignment 3 | Topology optimization

by

Timmy Ngo

October 1, 2023
Introduction
The assignment will be based on topology optimization of a compliance problem, i.e.

∫
1 1
min σ : ϵ dΩ (Strain Energy)
ρ 2 Ω 2

s.t. ρ ∈ [0, 1] (Material distr.)

∫
ρ dΩ ≤ V ∗ (Volume constraint)
Ω
∇·σ+F=0 (Balance law)

σ=C:ϵ (Hooke)

The sought problem is to investigate an aluminum flange subjected to a traction load depicted in
Fig. 1.1. Our task is to create a new geometry that fits within the given design space, and the given
volume constraint ≤ 50% of its original volume.

ty [mm]
3

y
10

10 80 10

Fig. 1.1: Steel flange in-plane load and boundary conditions.

The analyzed flange is a long member compared to the dimensions of the cross-section and is loaded
with a distributed load ty = 10 N. The geometry inherits symmetry properties, and the thickness t in
z−direction is t = 50 mm. Due to symmetry properties, the problem can also be analyzed using the
plane strain assumption.
The flange is made of isotropic aluminum material with the elastic modulus of E = 0.7 · 105 MPa,
and a Poisson’s ratio of ν = 0.33.
The following tasks are defined:
• First, run a static simulation of the black box. The student license of Abaqus is limited in
number of elements, but a mesh size of 0.0025 should give you a low enough number of elements.
Check the maximum deflection and stress.
The mesh, von Mises stresses, and displacements are seen in Fig. 1.2, Fig. 1.3, and Fig. 1.4.

1
 CHAPTER 1. INTRODUCTION

Fig. 1.2: 8 noded linear-brick elements.

S, Mises
(Avg: 75%)
+3.033e+02
+2.780e+02
+2.528e+02
+2.276e+02
+2.024e+02
+1.772e+02
+1.519e+02
+1.267e+02
+1.015e+02
+7.627e+01
+5.105e+01
+2.583e+01
+6.046e-01

ODB: Job-1.odb Abaqus/Standard 2023 Sun Oct 01 13:16:15 W. Europe Daylight Time 2023

Step: Step-1
Increment 1: Step Time = 1.000
Primary Var: S, Mises
Deformed Var: U Deformation Scale Factor: +3.537e+01

vM
Fig. 1.3: von Mises stresses, σmax = 30.3 MPa.

U, U2
+1.759e-03
-2.195e-02
-4.565e-02
-6.936e-02
-9.307e-02
-1.168e-01
-1.405e-01
-1.642e-01
-1.879e-01
-2.116e-01
-2.353e-01
-2.590e-01
-2.827e-01
Min: -2.827e-01
Node: BLACKBOX1-1.345

Min: -2.827e-01

ODB: Job-1.odb Abaqus/Standard 2023 Sun Oct 01 13:16:15 W. Europe Daylight Time 2023

Step: Step-1
Increment 1: Step Time = 1.000
Primary Var: U, U2
Deformed Var: U Deformation Scale Factor: +3.537e+01

Fig. 1.4: Maximum deflection in, u2 = −0.2827 mm.

2
 CHAPTER 1. INTRODUCTION

• Run a topology optimization. Preserve the geometry where the load and boundary conditions
are applied with the addition of a geometrical constraint that gives a draw direction from below
the bridge to the top. Run the topology optimization. Check the deflection.
The structure is seen in Fig. 1.5.

U, U2
+2.453e-03
-3.724e-02
-7.692e-02
-1.166e-01
-1.563e-01
-1.960e-01
-2.357e-01
-2.754e-01
-3.150e-01
-3.547e-01
-3.944e-01
-4.341e-01
-4.738e-01

ODB: Opt-Process-1-Job_post.odb Abaqus/Standard 2023 Sun Oct 01 17:32:19 W. Europe Daylight Time 20
Step: Step-1_Optimization, Step containing results of optimization design cycles for analysis step: Step-1, b
Optimization Design Cycle-47
Primary Var: U, U2
Deformed Var: U Deformation Scale Factor: +1 000e+01

Fig. 1.5: Topology optimization, maximum deflection in u′2 = −0.4738 mm.

• Run a static load analysis of your own geometry. Compare the deflection and stress levels of
your geometry and the first containing the entire black box.

U, U2
+8.404e-04
-5.546e-02
-1.118e-01
-1.681e-01
-2.244e-01
-2.807e-01
-3.370e-01
-3.933e-01
-4.496e-01
-5.059e-01
-5.622e-01
-6.185e-01
-6.748e-01

ODB: Job-1.odb Abaqus/Standard 2023 Sun Oct 01 18:46:51 W. Europe Daylight Time 2023
Step: Step-1
Increment 1: Step Time = 1.000
Primary Var: U, U2
Deformed Var: U Deformation Scale Factor: +7 000e+00

Fig. 1.6: Topology optimization, maximum deflection in u′2 = −0.6748 mm.

The stress level on the new geometry is not valid (von Mises stresses were up to 2·103 MPa) since
there are singularities, and numerical difficulties discretizing the fillets. The von Mises plot has
therefore been omitted. Instead, we include the displacements to compare the two cases. More
investigation in regards to the stresses is needed but due to the limited time, this is a delimitation.
The new geometry has the volume: V = 27046 mm3 , so the fraction is 27046/55000 = 0.4917%.