Crashworthiness design of periodic cellular structures using topology optimization

2021 ◽  
pp. 114164
Author(s):  
Jiao Jia ◽  
Daicong Da ◽  
Jianxing Hu ◽  
Sha Yin
Keyword(s):  
Topology Optimization ◽  
Cellular Structures ◽  
Crashworthiness Design

scholarly journals Multiscale, thermomechanical topology optimization of self-supporting cellular structures for porous injection molds

2019 ◽  
Vol 25 (9) ◽  
pp. 1482-1492
Author(s):  
Tong Wu ◽  
Andres Tovar
Keyword(s):  
Topology Optimization ◽  
Mechanical Performance ◽  
Mechanical Load ◽  
Design Method ◽  
Three Dimensional ◽  
Optimization Method ◽  
Cellular Structures ◽  
Injection Mold ◽  
Computationally Efficient ◽  
Content Type

Purpose This paper aims to establish a multiscale topology optimization method for the optimal design of non-periodic, self-supporting cellular structures subjected to thermo-mechanical loads. The result is a hierarchically complex design that is thermally efficient, mechanically stable and suitable for additive manufacturing (AM). Design/methodology/approach The proposed method seeks to maximize thermo-mechanical performance at the macroscale in a conceptual design while obtaining maximum shear modulus for each unit cell at the mesoscale. Then, the macroscale performance is re-estimated, and the mesoscale design is updated until the macroscale performance is satisfied. Findings A two-dimensional Messerschmitt Bolkow Bolhm (MBB) beam withstanding thermo-mechanical load is presented to illustrate the proposed design method. Furthermore, the method is implemented to optimize a three-dimensional injection mold, which is successfully prototyped using 420 stainless steel infiltrated with bronze. Originality/value By developing a computationally efficient and manufacturing friendly inverse homogenization approach, the novel multiscale design could generate porous molds which can save up to 30 per cent material compared to their solid counterpart without decreasing thermo-mechanical performance. Practical implications This study is a useful tool for the designer in molding industries to reduce the cost of the injection mold and take full advantage of AM.

Two-Scale Topology Optimization With Parameterized Cellular Structures

2021 ◽  
Author(s):  
Sina Rastegarzadeh ◽  
Jun Wang ◽  
Jida Huang
Keyword(s):  
Topology Optimization ◽  
High Resolution ◽  
Structural Optimization ◽  
Optimization Problem ◽  
Material Design ◽  
Homogenization Method ◽  
Elasticity Tensor ◽  
Structure Design ◽  
Cellular Structures ◽  
Mapping Technique

Abstract Advances in additive manufacturing enable the fabrication of complex structures with intricate geometric details. It also escalates the potential for high-resolution structure design. However, the increasingly finer design brings computational challenges for structural optimization approaches such as topology optimization (TO) since the number of variables to optimize increases with the resolutions. To address this issue, two-scale TO paves an avenue for high-resolution structural design. The design domain is first discretized to a coarse scale, and the material property distribution is optimized, then using micro-structures to fill each property field. In this paper, instead of finding optimal properties of two scales separately, we reformulate the two-scale TO problem and optimize the design variables concurrently in both scales. By introducing parameterized periodic cellular structures, the minimal surface level-parameter is defined as the material design parameter and is implemented directly in the optimization problem. A numerical homogenization method is employed to calculate the elasticity tensor of the cellular materials. The stiffness matrices of the cellular structures derived as a function of the level parameters, using the homogenization results. An additional constraint on the level parameter is introduced in the structural optimization framework to enhance adjacent cellulars interfaces’ compatibility. Based on the parameterized micro-structure, the optimization problem is solved concurrently with an iterative solver. The reliability of the proposed approach has been validated with different engineering design cases. Numerical results show a noticeable increase in structure stiffness using the level parameter directly in the optimization problem than the state-of-art mapping technique.

Topology optimization in crashworthiness design

2006 ◽  
Vol 33 (1) ◽  
pp. 1-12 ◽  
Author(s):  
Jimmy Forsberg ◽  
Larsgunnar Nilsson
Keyword(s):  
Topology Optimization ◽  
Crashworthiness Design

Crashworthiness Design Using Topology Optimization

2009 ◽  
Vol 131 (6) ◽  
Author(s):  
Neal M. Patel ◽  
Byung-Soo Kang ◽  
John E. Renaud ◽  
Andrés Tovar
Keyword(s):  
Topology Optimization ◽  
Design Space ◽  
Three Dimensional ◽  
Manufacturing Cost ◽  
Optimization Approach ◽  
Maximum Displacement ◽  
Efficient Manner ◽  
Response Surface Approximations ◽  
Cost Constraints ◽  
Crashworthiness Design

Crashworthiness design is an evolving discipline that combines vehicle crash simulation and design synthesis. The goal is to increase passenger safety subject to manufacturing cost constraints. The crashworthiness design process requires modeling of the complex interactions involved in a crash event. Current approaches utilize a parametrized optimization approach that requires response surface approximations of the design space. This is due to the expensive nature of numerical crash simulations and the high nonlinearity and noisiness in the design space. These methodologies usually require a significant effort to determine an initial design concept. In this paper, a heuristic approach to continuum-based topology optimization is developed for crashworthiness design. The methodology utilizes the cellular automata paradigm to generate three-dimensional design concepts. Furthermore, a constraint on maximum displacement is implemented to maintain a desired performance of the structures synthesized. Example design problems are used to demonstrate that the proposed methodology converges to a final topology in an efficient manner.

Multiscale topology optimization for graded cellular structures based on level set surface cutting

2022 ◽  
Vol 65 (1) ◽  
Author(s):  
Chen Yu ◽  
Qifu Wang ◽  
Zhaohui Xia ◽  
Yingjun Wang ◽  
Chao Mei ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Level Set ◽  
Cellular Structures

Topology optimization of adaptive fluid-actuated cellular structures with arbitrary polygonal motor cells

2016 ◽  
Vol 25 (5) ◽  
pp. 055021 ◽  
Author(s):  
Jun Lv ◽  
Liang Tang ◽  
Wenbo Li ◽  
Lei Liu ◽  
Hongwu Zhang
Keyword(s):  
Topology Optimization ◽  
Cellular Structures ◽  
Motor Cells
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