scholarly journals Level Set Topology Optimization of Printed Active Composites

2015 ◽  
Vol 137 (11) ◽  
Author(s):  
Kurt Maute ◽  
Anton Tkachuk ◽  
Jiangtao Wu ◽  
H. Jerry Qi ◽  
Zhen Ding ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Shape Memory ◽  
Level Set ◽  
Spatial Arrangement ◽  
Optimization Method ◽  
Optimization Approach ◽  
Target Shape ◽  
3D Printed ◽  
Residual Strains ◽  
Material Layout

Multimaterial polymer printers allow the placement of different material phases within a composite, where some or all of the materials may exhibit an active response. Utilizing the shape memory (SM) behavior of at least one of the material phases, active composites can be three-dimensional (3D) printed such that they deform from an initially flat plate into a curved structure. This paper introduces a topology optimization approach for finding the spatial arrangement of shape memory polymers (SMPs) within a passive matrix such that the composite assumes a target shape. The optimization approach combines a level set method (LSM) for describing the material layout and a generalized formulation of the extended finite-element method (XFEM) for predicting the response of the printed active composite (PAC). This combination of methods yields optimization results that can be directly printed without the need for additional postprocessing steps. Two multiphysics PAC models are introduced to describe the response of the composite. The models differ in the level of accuracy in approximating the residual strains generated by a thermomechanical programing process. Comparing XFEM predictions of the two PAC models against experimental results suggests that the models are sufficiently accurate for design purposes. The proposed optimization method is studied with examples where the target shapes correspond to a plate-bending type deformation and to a localized deformation. The optimized designs are 3D printed and the XFEM predictions are compared against experimental measurements. The design studies demonstrate the ability of the proposed optimization method to yield a crisp and highly resolved description of the optimized material layout that can be realized by 3D printing. As the complexity of the target shape increases, the optimal spatial arrangement of the material phases becomes less intuitive, highlighting the advantages of the proposed optimization method.

scholarly journals Optimization of Brake Calipers Using Topology Optimization for Additive Manufacturing

2021 ◽  
Vol 11 (4) ◽  
pp. 1437
Author(s):  
Evangelos Tyflopoulos ◽  
Mathias Lien ◽  
Martin Steinert
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Procedure ◽  
Optimization Approach ◽  
Design Flexibility ◽  
Current State ◽  
3D Printed ◽  
Removal Processes ◽  
Material Layout

The weight optimization of a structure can be conducted by using fewer and downsized components, applying lighter materials in production, and removing unwanted material. Topology optimization (TO) is one of the most implemented material removal processes. In addition, when it is oriented towards additive manufacturing (AM), it increases design flexibility. The traditional optimization approach is the compliance optimization, where the material layout of a structure is optimized by minimizing its overall compliance. However, TO, in its current state of the art, is mainly used for design inspiration and not for manufacturing due to design complexities and lack of accuracy of its design solutions. The authors, in this research paper, explore the benefits and the limitations of the TO using as a case study the housings of a front and a rear brake caliper. The calipers were optimized for weight reduction by implementing the aforementioned optimization procedure. Their housings were topologically optimized, partially redesigned, prepared for 3D printing, validated, and 3D printed in titanium using selective laser melting (SLM). The weight of the optimized calipers reduced by 41.6% compared to commercial calipers. Designers interested in either TO or in automotive engineering can exploit the findings in this paper.

Optimal Level Set Vibration Control of Plate Structures

2011 ◽  
Author(s):  
Masoud Ansari ◽  
Amir Khajepour ◽  
Ebrahim Esmailzadeh
Keyword(s):  
Topology Optimization ◽  
Level Set ◽  
Vibration Suppression ◽  
Optimization Method ◽  
Optimal Level ◽  
Optimum Shape ◽  
Optimization Approach ◽  
Constrained Layer Damping ◽  
Fundamental Vibration ◽  
Flexural Vibrations

This research is motivated by the need for control of flexural vibrations of lightweight plates. It addresses application of the level set method in optimal control of vibrations in plate-like structures. One of the most commonly practiced methods in control of vibration is to apply constrained layer damping patches to the surface of a structure. In order to consider the weight efficiency of the structure, the best shape and locations of the patches should be determined to achieve the optimum vibration suppression with lowest amount of damping patch. A novel topology optimization approach is proposed that is capable of finding the optimum shape and locations of the patches simultaneously. A 2D cantilever plate, undergoing flexural vibrations, will be considered. The optimal damping set will be found in the structure, such that the lowest modal energy in the fundamental vibration mode of the system is achieved. The proposed level set topology optimization method shows capability of determining the optimum damping set in structures accurately.

Optimal Viscous Damper Placement Using Level Set Topology Optimization Method

2010 ◽  
Author(s):  
Masoud Ansari ◽  
Amir Khajepour ◽  
Ebrahim Esmailzadeh
Keyword(s):  
Topology Optimization ◽  
Level Set ◽  
Discrete Optimization ◽  
Optimization Problem ◽  
Minimum Energy ◽  
Optimization Method ◽  
Discrete Optimization Problem ◽  
Placement Problem ◽  
New Approach ◽  
Optimal Damping

Vibration control has always been of great interest for many researchers in different fields, especially mechanical and civil engineering. One of the key elements in control of vibration is damper. One way of optimally suppressing unwanted vibrations is to find the best locations of the dampers in the structure, such that the highest dampening effect is achieved. This paper proposes a new approach that turns the conventional discrete optimization problem of optimal damper placement to a continuous topology optimization. In fact, instead of considering a few dampers and run the discrete optimization problem to find their best locations, the whole structure is considered to be connected to infinite numbers of dampers and level set topology optimization will be performed to determine the optimal damping set, while certain number of dampers are used, and the minimum energy for the system is achieved. This method has a few major advantages over the conventional methods, and can handle damper placement problem for complicated structures (systems) more accurately. The results, obtained in this research are very promising and show the capability of this method in finding the best damper location is structures.

scholarly journals A local solution approach for level-set based structural topology optimization in isogeometric analysis

2020 ◽  
Vol 7 (4) ◽  
pp. 514-526
Author(s):  
Zijun Wu ◽  
Shuting Wang ◽  
Renbin Xiao ◽  
Lianqing Yu
Keyword(s):  
Topology Optimization ◽  
Level Set ◽  
Isogeometric Analysis ◽  
Iteration Process ◽  
Solid Material ◽  
Optimization Approach ◽  
Structural Topology ◽  
Zero Level ◽  
Solution Approach ◽  
Level Set Function

Abstract This paper develops a new topology optimization approach for minimal compliance problems based on the parameterized level set method in isogeometric analysis. Here, we choose the basis functions as level set functions. The design variables are obtained with Greville abscissae based on the corresponding collocation points. The zero-level set boundaries are derived from the level set function values of the interpolation points in all knot spans. In the optimization iteration process, the whole design domain is discretized into two types of subdomains around the zero-level set boundaries, undesign area with void materials and redesign domain with solid materials. To decrease the size of equations and the computational consumptions, only the solid material area is recalculated and the void material area is discarded according to the high accuracy of isogeometric analysis. Numerical examples demonstrate the validity of the proposed optimization method.

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