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Topology Optimization in Engineering Structure Design
Series Editor
Piotr Breitkopf
Topology Optimization in
Engineering Structure Design
Weihong Zhang
Jihong Zhu
Tong Gao
First published 2016 in Great Britain and the United States by ISTE Press Ltd and Elsevier Ltd
Apart from any fair dealing for the purposes of research or private study, or criticism or review, as
permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced,
stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers,
or in the case of reprographic reproduction in accordance with the terms and licenses issued by the
CLA. Enquiries concerning reproduction outside these terms should be sent to the publishers at the
undermentioned address:
Notices
Knowledge and best practice in this field are constantly changing. As new research and experience
broaden our understanding, changes in research methods, professional practices, or medical treatment
may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in evaluating and
using any information, methods, compounds, or experiments described herein. In using such information
or methods they should be mindful of their own safety and the safety of others, including parties for
whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any
liability for any injury and/or damage to persons or property as a matter of products liability, negligence
or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in
the material herein.
– AVIC, China
In the 21st Century, many new aircraft and aerospace projects are
being set up in China. This brings great challenges in developing
innovative design methodology and dealing with new scientific and
technical problems issued from the complicated engineering practices.
Nowadays, industrial applications are becoming one of the most
important challenges in the engineering design community of structure
optimization, especially topology optimization for aircraft or
aerospace structure systems. Within this scope, fundamental and
innovative research works are carried out. The research team of
Engineering Simulation & Aerospace Computing in Northwestern
Polytechnical University in China is becoming one of the most active
research groups in this discipline and is motivated to develop the
following techniques and solutions.
ep
es
ha
ea
et
R 4
Skin
I-section
Truss rib
Figure I.1. Sizing optimization for aircraft structure members [RAD 02]
Introduction xiii
Figure
e I.3. A typicall topology optiimization prob
blem of MBB-b
beam [BEN 03
3]
Macrostructure
Microstructure
Ei = E0ηip [I.1]
ηi
Ei = E0 [I.2]
1 + q (1 −ηi )
[WAN 03, ALL 04b, DER 04, MEI 04a, MEI 04b] were developed to
describe the structure as a high dimension level-set function.
and motivation is presented first. Then the state of art of the related
techniques and their applications is reviewed. In the following
chapters, contents are related to standard material layout design with
topology optimization, low-density areas in topology optimization,
dynamic and thermal-elastic design of topology optimization,
integrated layout design of multicomponent system and topology
optimization with constraints on multifastener joint loads. Finally,
potential applications of topology optimization, such as shape
preserving design, smart structure design, structural feature design and
additive manufacturing, etc., are also addressed to provide a forward-
looking perspective.
1
Fixations
Hanging positions
Figure 1.2. The design domain and its finite element model
1 1
C = FT U = ( F m + Fg ) U
T
min : [1.2]
2 2
where C is the strain energy in terms of the external load vector Fm,
the self-weight load vector Fg and the nodal displacement vector U. F
is the total nodal load vector. It is important to note that Fg is design
dependent and follows the general rule of no material, no load. The
finite element equilibrium equation corresponds to
Fm + Fg = KU [1.3]
V and VU denote the total volume of the material and the upper
bound, respectively. The combination of equation [1.2] with equation
[1.4] constitutes the standard topology optimization formulation.
ρi = ηi ρi 0
[1.5]
Ei = P(ηi ) Ei 0 = ( (1 − w)ηip + wηi ) Ei 0
4 Topology Optimization in Engineering Structure Design
where ρi0 and Ei0 are the specific density and elastic modulus of
solid material, respectively. P(ηi) can be considered as an extended
SIMP with w and p being constant parameters of the interpolation.
Details of this interpolation model are discussed in the following
chapters.
⎡ ⎤
∂C 1 ⎢ ∂ ( F )
g T
∂V g T ∂U ⎥
= Vi 0 ; = U + (F + F )
m
⎧⎪ ∂C ⎫⎪
⎛ ∂C ⎞
* ∑j ⎨η j ⎡⎣rmin − dis( j, i) ⎤⎦ ∂η j ⎬
⎩⎪ ⎭⎪
⎜ ⎟ = [1.7]
⎝ ∂ηi ⎠ ηi ∑ ⎡⎣ rmin − dis( j, i) ⎤⎦
j
{
η j ∈ η j dis( j , i ) ≤ rmin }
Standard Material Layout Design 5
where dis(j,i) refers to the distance between the jth and ith density
points. All the density points located within the predefined distance
rmin are accounted for in the filtering scheme.
⎛ 1 1 ⎞
+∑ qi( k ) ⎜⎜ − ⎟
i ⎝ xi − li
(k )
xi( k ) − li( k ) ⎟⎠
For the optimization problem shown in Figure 1.2, the final design
obtained using GCMMA is shown in Figure 1.3. The material
distribution of the optimized design indicates the most effective load
carrying path that can be used as an important reference for the further
detailed design.
6 Topology Opttimization in Engineering Structure Design
It has frequently been observed that Genius and Madness are nearly allied;
that very great talents are seldom found unaccompanied by a touch of
insanity, and that there are few bedlamites who will not, upon a close
examination, display symptoms of a powerful, though ruined, intellect.
According to this hypothesis, the flowers of Parnassus must be blended
with the drugs of Anticyra; and the man who feels himself to be in
possession of very brilliant wits may conclude that he is within an ace of
running out of them. Whether this be true or false, we are not at present
disposed to contradict the assertion. What we wish to notice is the pains
which many young men take to qualify themselves for Bedlam, by hiding a
good, sober, gentleman-like understanding beneath an assumption of
thoughtlessness and whim. It is the received opinion among many that a
man’s talents and abilities are to be rated by the quantity of nonsense he
utters per diem, and the number of follies he runs into per annum. Against
this idea we must enter our protest; if we concede that every real genius is
more or less a madman, we must not be supposed to allow that every sham
madman is more or less a genius.
In the days of our ancestors, the hot-blooded youth who threw away his
fortune at twenty-one, his character at twenty-two, and his life at twenty-
three, was termed “a good fellow,” “an honest fellow,” “nobody’s enemy
but his own.” In our time the name is altered; and the fashionable who
squanders his father’s estate, or murders his best friend—who breaks his
wife’s heart at the gaming-table, and his own neck at a steeple-chase—
escapes the sentence which morality would pass upon him, by the plea of
lunacy. “He was a rascal,” says Common Sense. “True,” says the World,
“but he was mad, you know—quite mad.”
We were lately in company with a knot of young men who were
discussing the character and fortunes of one of their own body, who was, it
seems, distinguished for his proficiency in the art of madness. “Harry,” said
a young sprig of nobility, “have you heard that Charles is in the King’s
Bench?” “I heard it this morning,” drawled the Exquisite; “how distressing!
I have not been so hurt since poor Angelica (his bay mare) broke down.
Poor Charles has been too flighty.” “His wings will be clipped for the
furture!” observed young Caustic. “He has been very imprudent,” said
young Candour.
I inquired of whom they were speaking. “Don’t you know Charles
Gally?” said the Exquisite, endeavouring to turn in his collar. “Not know
Charles Gally?” he repeated, with an expression of pity. “He is the best
fellow breathing; only lives to laugh and make others laugh; drinks his two
bottles with any man, and rides the finest mare I ever saw—next to my
Angelica. Not know Charles Gally? Why everybody knows him! He is so
amusing! Ha! ha! And tells such admirable stories! Ha! ha! Often have they
kept me awake”—a yawn—“when nothing else could.” “Poor fellow!” said
his lordship; “I understand he’s done for ten thousand!” “I never believe
more than half what the world says,” observed Candour. “He that has not a
farthing,” said Caustic, “cares little whether he owes ten thousand or five.”
“Thank Heaven!” said Candour, “that will never be the case with Charles:
he has a fine estate in Leicestershire.” “Mortgaged for half its value,” said
his lordship. “A large personal property!” “All gone in annuity bills,” said
the Exquisite. “A rich uncle upwards of fourscore!” “He’ll cut him off with
a shilling,” said Caustic.
“Let us hope he may reform,” sighed the Hypocrite; “and sell the pack,”
added the Nobleman; “and marry,” continued the Dandy. “Pshaw!” cried the
Satirist, “he will never get rid of his habits, his hounds, or his horns.” “But
he has an excellent heart,” said Candour. “Excellent,” repeated his lordship,
unthinkingly. “Excellent,” lisped the Fop, effeminately. “Excellent,”
exclaimed the Wit, ironically. We took this opportunity to ask by what
means so excellent a heart and so bright a genius had contrived to plunge
him into these disasters. “He was my friend,” replied his lordship, “and a
man of large property; but he was mad—quite mad. I remember his leaping
a lame pony over a stone wall, simply because Sir Marmaduke bet him a
dozen that he broke his neck in the attempt; and sending a bullet through a
poor pedlar’s pack because Bob Darrell said the piece wouldn’t carry so
far.” “Upon another occasion,” began the Exquisite in his turn, “he jumped
into a horse-pond after dinner in order to prove it was not six feet deep; and
overturned a bottle of eau-de-cologne in Lady Emilia’s face, to convince me
that she was not painted. Poor fellow! The first experiment cost him a dress,
and the second an heiress.” “I have heard,” resumed the Nobleman, “that he
lost his election for—— by lampooning the mayor; and was dismissed from
his place in the Treasury for challenging Lord C——.” “The last accounts I
heard of him,” said Caustic, “told me that Lady Tarrel had forbid him her
house for driving a sucking-pig into her drawing-room; and that young
Hawthorn had run him through for boasting of favours from his sister!”
“These gentlemen are really too severe,” remarked young Candour to us.
“Not a jot,” we said to ourselves.
“This will be a terrible blow for his sister,” said a young man who had
been listening in silence. “A fine girl—a very fine girl,” said the Exquisite.
“And a fine fortune,” said the Nobleman; “the mines of Peru are nothing to
her.” “Nothing at all,” observed the Sneerer; “she has no property there. But
I would not have you caught, Harry; her income was good, but is dipped,
horribly dipped. Guineas melt very fast when the cards are put by them.” “I
was not aware Maria was a gambler,” said the young man, much alarmed.
“Her brother is, Sir,” replied his informant. The querist looked sorry, but yet
relieved. We could see that he was not quite disinterested in his inquiries.
“However,” resumed the young Cynic, “his profusion has at least obtained
him many noble and wealthy friends.” He glanced at his hearers, and went
on: “No one that knew him will hear of his distresses without being forward
to relieve them. He will find interest for his money in the hearts of his
friends.” Nobility took snuff; Foppery played with his watch-chain;
Hypocrisy looked grave. There was long silence. We ventured to regret the
misuse of natural talents, which, if properly directed, might have rendered
their possessor useful to the interests of society and celebrated in the
records of his country. Every one stared, as if we were talking Hebrew.
“Very true,” said his lordship, “he enjoys great talents. No man is a nicer
judge of horseflesh. He beats me at billiards, and Harry at picquet; he’s a
dead shot at a button, and can drive his curricle-wheels over a brace of
sovereigns. “Radicalism,” says Caustic, looking round for a laugh. “He is a
great amateur of pictures,” observed the Exquisite, “and is allowed to be
quite a connoisseur in beauty; but there,” simpering, “every one must claim
the privilege of judging for themselves.” “Upon my word,” said Candour,
“you allow poor Charles too little. I have no doubt he has great courage—
though, to be sure, there was a whisper that young Hawthorn found him
rather shy; and I am convinced he is very generous, though I must confess
that I have it from good authority that his younger brother was refused the
loan of a hundred when Charles had pigeoned that fool of a nabob but the
evening before. I would stake my existence that he is a man of unshaken
honour—though, when he eased Lieutenant Hardy of his pay, there
certainly was an awkward story about the transaction, which was never
properly cleared up. I hope that when matters are properly investigated he
will be liberated from all his embarrassments; though I am sorry to be
compelled to believe that he has been spending double the amount of his
income annually. But I trust that all will be adjusted. I have no doubt upon
the subject.” “Nor I,” said Caustic. “We shall miss him prodigiously at the
Club,” said the Dandy, with a slight shake of the head. “What a bore!”
replied the Nobleman, with a long yawn. We could hardly venture to
express compassion for a character so despicable. Our auditors, however,
entertained very different opinions of right and wrong! “Poor fellow! he
was much to be pitied: had done some very foolish things—to say the truth
was a sad scoundrel—but then he was always so mad.” And having come
unanimously to this decision, the conclave dispersed.
Charles gave an additional proof of his madness within a week after this
discussion by swallowing laudanum. The verdict of the coroner’s inquest
confirmed the judgment of his four friends. For our own parts we must
pause before we give in to so dangerous a doctrine. Here is a man who has
outraged the laws of honour, the ties of relationship, and the duties of
religion; he appears before us in the triple character of a libertine, a
swindler, and a suicide. Yet his follies, his vices, his crimes, are all palliated
or even applauded by this specious façon de parler—“He was mad—quite
mad!”