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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Simultaneous shape and topology optimization of inflatable soft robots

Simultaneous shape and topology optimization is used to design pressure-activated inflatable soft robots. The pressure loaded boundary is meshed conformingly and shape optimized, while the morphology of the robot is topology optimized. The design objective is to exert maximum force on an object, i.e. to produce soft “grippers”. The robot’s motion is modeled using nearly incompressible finite deformation hyperelasticity. To ensure stability of the robot, the buckling load factors obtained via linearized buckling analyses are constrained. The finite element method is used to evaluate the optimization cost and constraint functions and the adjoint method is employed to compute their sensitivities. The numerical examples produce pressure-driven soft robots with varying complexity. We also compare our simultaneous optimization results to those obtained via sequential topology and then shape optimization.

42 ENGINEERING↗
DOE OSTI2022

Minimum feature size control in level set topology optimization via density fields

A level set topology optimization approach that uses an auxiliary density field to nucleate holes during the optimization process and achieves minimum feature size control in optimized designs is explored. The level set field determines the solid-void interface and the density field describes the distribution of a fictitious porous material using the solid isotropic material with penalization. These fields are governed by two sets of independent optimization variables which are initially coupled using a penalty for hole nucleation. The strength of the density field penalization and projection is gradually increased during the optimization process to promote a 0-1 density distribution. In addition, a second penalty regulates the evolution of the density field in the void phase. The treatment of the density field combined with the second penalty mitigate the appearance of small design features. The minimum feature size of optimized designs is controlled by the radius of the linear filter applied to the density optimization variables. The structural response is predicted by the extended finite element method, the sensitivities by the adjoint method, and the optimization variables are updated by a gradient-based optimization algorithm. Numerical examples investigate the robustness of this approach with respect to algorithmic parameters and mesh refinement. The results show the applicability of the combined density level set topology optimization approach for both optimal hole nucleation and for minimum feature size control in 2D and 3D. This comes, however, at the cost of a more complex problem formulation and additional computational cost due to an increased number of optimization variables.

42 ENGINEERING↗
DOE OSTI2020

An error-in-constitutive equations strategy for topology optimization for frequency-domain dynamics

This paper presents a topology optimization formulation for frequency-domain dynamics to reduce solution dependence upon initial guess and considered loading conditions. Due to resonance phenomena in undamped steady-state dynamics, objectives measuring dynamic response possess many local minima that may represent poor solutions to a design problem, an issue exacerbated for design with respect to multiple frequencies. In this work, we propose an extension of the modified error-in-constitutive-equations (MECE) method, used previously in material identification inverse problems, as a new approach for frequency-domain dynamics topology optimization to mitigate these issues. The main idea of the proposed framework is to incorporate an additional penalty-like term in the objective function that measures the discrepancy in the constitutive relations between stresses and strains and between inertial forces and displacements. Then, the design problem is cast within a PDE-constrained optimization formulation in which we seek displacements, stresses, inertial forces, and a density-field solution that minimize our new objective subject to conservation of linear momentum plus some additional constraints. We show that this approach yields superior designs to conventional gradient-based optimization approaches that solely use a functional of displacements as the objective, while strictly enforcing the constitutive equations. The MECE strategy integrates into a density-based topology optimization scheme for void–solid or two-phase material structural design. We highlight the merits of our approach in a variety of scenarios for direct frequency response design, considering multiple frequency load cases and structural objectives.

42 ENGINEERING↗
NASA NTRS2017

Uncertainty Aware Structural Topology Optimization Via a Stochastic Reduced Order Model Approach

This work presents a stochastic reduced order modeling strategy for the quantification and propagation of uncertainties in topology optimization. Uncertainty aware optimization problems can be computationally complex due to the substantial number of model evaluations that are necessary to accurately quantify and propagate uncertainties. This computational complexity is greatly magnified if a high-fidelity, physics-based numerical model is used for the topology optimization calculations. Stochastic reduced order model (SROM) methods are applied here to effectively 1) alleviate the prohibitive computational cost associated with an uncertainty aware topology optimization problem; and 2) quantify and propagate the inherent uncertainties due to design imperfections. A generic SROM framework that transforms the uncertainty aware, stochastic topology optimization problem into a deterministic optimization problem that relies only on independent calls to a deterministic numerical model is presented. This approach facilitates the use of existing optimization and modeling tools to accurately solve the uncertainty aware topology optimization problems in a fraction of the computational demand required by Monte Carlo methods. Finally, an example in structural topology optimization is presented to demonstrate the effectiveness of the proposed uncertainty aware structural topology optimization approach.

Aguilo, Miguel A.↗
DOE OSTI2017

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. In conclusion, 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.

42 ENGINEERING↗
NASA NTRS2019

A Mixed Integer Efficient Global Optimization Algorithm with Multiple Infill Strategy - Applied to a Wing Topology Optimization Problem

With the advancement in high performance computing and numerical optimization techniques,engineering design optimization problems are becoming more complex, larger scale,higher fidelity, and computationally more demanding, requiring longer run times than ever before. There exists methodologies and techniques that can address some of these challenges but very few can address all, and most are limited in the extent that these concerns can be addressed. With the goal of addressing such challenging engineering problems, we developed anew optimization framework, named AMIEGO, that combines concepts from surrogate-based optimization approaches, gradient-based numerical methods, Partial Least Squares, evolutionary algorithms, and Branch-and-Bound, providing newer capabilities that were not previouslyperceived. However, the original version of this framework, in the process of adaptive samplingto explore and exploit the design space, finds only a single sample point per iteration. The efforthere builds upon this previously developed optimization framework to include multiple infillsampling capability that combines the concept of generalized expected improvement function,unsupervised learning, and multi-objective evolutionary technique. To demonstrate, AMIEGOwith the multiple infill capability (called AMIEGO-MIMOS) solves a series of increasingly difficultengineering design optimization problems. The results reveal the performance of the newapproach is problem dependent. When applied to a ten-bar truss problem, the newly proposedmultiple infill strategy consistently leads to a better design solutions when compared to theexisting CPTV method (implemented with the context of the AMIEGO framework). On theother hand, when applied to a mixed-integer high fidelity wing topology optimization problem- MIMOS, despite showing a steeper convergence at the start, eventually leads to an inferiorsolution as compared to CPTV approach. These results also reveal that a small number ofstarting points, in general, are sufficient to lead to a good overall solution.

Mixed-integer optimization↗
DOE OSTI2021

Substation-Level Grid Topology Optimization Using Bus Splitting: Preprint

Operations of substation circuit breakers are of high significance for performing system maintenance and topology optimization. Bus splitting is one type of topology changes where the two bus-bars at a substation become electrically disconnected after certain actions of circuit breakers. As these events involve detailed substation modeling, they are not typically considered in power system routine operation and control. In this paper, an improved substation-level topology optimization is developed by expanding traditional line switching with breaker-level bus splitting, which can further reduce grid congestion and generation costs. A tight McCormick relaxation is proposed to reformulate the bi-linear terms in the resultant topology optimization model. Thus, a tractable mixed-integer linear program formulation is presented which can be efficiently solved for real-time control. Numerical studies on the IEEE 14-bus and 118-bus systems demonstrate the performance and economic benefits of the proposed topology optimization approach.

bus split↗
NASA NTRSDate not supplied

Design of a Wind Tunnel Balance using Topology Optimization Considering Multifunctional Stress Performance

This paper proposes a new topology optimization formulation for multi-functional performance of a compliant sensor structure–a wind tunnel balance. Compliant mechanism design is one of the main applications of topology optimization and plenty of successful design studies have been reported. However, design practicability is still questionable when stress concentration is critical due to complex/combined loads, especially at compliant hinge joints. In this paper, we formulate a new topology optimization formulation considering multiple loading scenarios in a compliant sensor structure design. Two separate constraints,one related to sensor performance and the other focused on structural safety in terms of maximum von Mises stress, are included in the design formulation. This formulation is to achieve excellent sensitivity of an applied axial load while maintaining structure safety with a combined general load applied which is one order higher than the axial load. This challenging problem is solved using a well-known SIMP approach with the relaxation and projection methods.

Myung Kyun Sung↗
DOE OSTI2020

Consistent boundary conditions for PDE filter regularization in topology optimization

Abstract Design variables in density-based topology optimization are typically regularized using filtering techniques. In many cases, such as stress optimization, where details at the boundaries are crucially important, the filtering in the vicinity of the design domain boundary needs special attention. One well-known technique, often referred to as “padding,” is to extend the design domain with extra layers of elements to mitigate artificial boundary effects. We discuss an alternative to the padding procedure in the context of PDE filtering. To motivate this augmented PDE filter, we make use of the potential form of the PDE filter which allows us to add penalty terms with a clear physical interpretation. The major advantages of the proposed augmentation compared with the conventional padding is the simplicity of the implementation and the possibility to tune the boundary properties using a scalar parameter. Analytical results in 1D and numerical results in 2D and 3D confirm the suitability of this approach for large-scale topology optimization.

42 ENGINEERING↗
DOE OSTI2018

Matlab Code for Multiscale Topology Optimization

This Matlab script implements a simple topology optimization algorithm that minimizes the compliance of a structure within a 3D prismatic design domain. It uses a simple linear elastic finite element solver to solve the equilibrium equations, and the optimality criterion (00) method to update the design iteratively. This functionality is identical to, or the simplest possible extension from 2D to 3D of, a 99-line Matlab code released in 2001 in a journal article by Sigmund. What is new in this code is our implementation of simple surrogate models for several truss micro-architectures, which converts this code to a multiscale design tool, whereas the original code is single-scale. The development of these surrogate models and their implementation is described in a journal article we intend to submit. We plan to include the full source code in an Appendix in this paper. The code’s primary function is as a pedagogical tool rather than as a finished software product. Sigmund’s 2001 paper describes the implementation line-by-line. We are including this updated version of the code to allow the reader to understand exactly what changes must be made to a “standard” topology optimization code to implement the surrogate models and thus multiscale design optimization.

Watts, Seth↗
DOE OSTI2018

Review of Shape and Topology Optimization for Design of Air-to-Refrigerant Heat Exchangers

Air-to-refrigerant heat exchangers (HXs) have been the topic of exhaustive research as they are fundamental components of HVAC&R systems. It has been well-established that the large airside thermal resistance dominates the HX thermal resistance, and thus significant research efforts have focused on improving the air-side performance of these heat exchangers. As HXs continue to become more compact, thermal resistance reduction is typically realized through the utilization of extended secondary heat transfer surfaces such as fins. However, past research has shown that the thermal-hydraulic trade-offs provided by fins are often not attractive enough to warrant their use, especially for small diameter tubes. Yet, the inadequate primary surface area provided by compact HXs essentially mandate the necessity of fins to meet thermal resistance requirements. In recent years, advancements in computational tools such as Computational Fluid Dynamics (CFD) and optimization algorithms, coupled with the advent of additive manufacturing technologies, have allowed engineers to expand conventional HX design ideologies to include such concepts as shape and topology optimization. This lends itself directly to primary heat transfer surface optimization and even the potential removal of finned surfaces altogether. This paper presents a comprehensive literature review investigating air-to-refrigerant HX shape and topology optimization. The fundamentals of both shape and topology optimization, model development, and experimental validations are all separately discussed. Studies featuring manufactured prototypes and/or experimentally validated optimal designs are treated with additional emphasis. This paper concludes by identifying key research gaps and proposing future research directions for HX shape and topology optimization.

42 ENGINEERING↗
DOE OSTI2025

Analysis of the SiMPL Method for Density-Based Topology Optimization

We present a rigorous convergence analysis of a new method for density-based topology optimization that provides pointwise bound-preserving design updates and faster convergence than other popular first-order topology optimization methods. Due to its strong bound preservation, the method is exceptionally robust, as demonstrated in numerous examples here and in the companion article [D. Kim et al., Struct. Multidiscip. Optim., 68 (2025), 74]. Furthermore, it is easy to implement with clear structure and analytical expressions for the updates. Our analysis covers two versions of the method, characterized by the employed line search strategies. We consider a modified Armijo backtracking line search and a Bregman backtracking line search. For both line search algorithms, our algorithm delivers a strict monotone decrease in the objective function and further intuitive convergence properties, e.g., strong and pointwise convergence of the density variables on the active sets, norm convergence to zero of the increments, convergence of the Lagrange multipliers, and more. In addition, the numerical experiments demonstrate apparent mesh-independent convergence of the algorithm. Here, we refer to the new algorithm as the SiMPL method (pronounced “simple”), which stands for Sigmoidal Mirror descent with a Projected Latent variable.

97 MATHEMATICS AND COMPUTING↗
NASA NTRSDate not supplied

On The Incorporation of Both Function-Driven Requirements and Topology Optimization in The Development of Lunar Launch & Landing Pads

In the design of additively manufactured structures, there can be a constant battle between focusing on function-driven design and topology optimization in an attempt to improve a products ability to meet all requirements. Function-driven optimization is defined as the process of identifying the best design parameters that satisfy project functionality requirements. Function-driven optimization is typically implemented by a designer(s) who, instead of computational limitations, has human bias for the input or inputs determined. On the other hand, topology optimization is defined as a mathematical method that optimizes material layout within a given design space, for a given set of loads, boundary conditions, and constraints with the goal of maximizing the performance of the system. In topology optimization, the work is defined by the limited mathematical inputs and computationally available goals/restraints. If not evaluated simultaneously, these two approaches can result in fundamentally different design concepts meant to address the same requirements. NASA’s Artemis program includes the development of a base camp near the lunar South Pole. After site selection is made, one of the first infrastructure elements needed will be a launch and landing pad (LLP). The construction of such a pad will prevent damage to nearby structures from plume-surface interaction (PSI) while also providing a stable platform for the lander. These benefits reduce the required distance between the established landing zones and other settlement infrastructure. In this paper, the authors evaluate the requirements associated with lunar LLP development, application of both functional and topological optimization techniques, methodologies to combine the two techniques, and potential impacts on final design of such a pad.

In-situ↗
DOE OSTI2020

Scalable Deep-Learning-Accelerated Topology Optimization for Additively Manufactured Materials

Topology optimization (TO) is a popular and powerful computational approach for designing novel structures, materials, and devices. Two computational challenges have limited the applicability of TO to a variety of industrial applications. First, a TO problem often involves a large number of design variables to guarantee sufficient expressive power. Second, many TO problems require a large number of expensive physical model simulations, and those simulations cannot be parallelized. To address these issues, we propose a general scalable deep-learning (DL) based TO framework, referred to as SDL-TO, which utilizes parallel schemes in high performance computing (HPC) to accelerate the TO process for designing additively manufactured (AM) materials. Unlike the existing studies of DL for TO, our framework accelerates TO by learning the iterative history data and simultaneously training on the mapping between the given design and its gradient. The surrogate gradient is learned by utilizing parallel computing on multiple CPUs incorporated with a distributed DL training on multiple GPUs. The learned TO gradient enables a fast online update scheme instead of an expensive update based on the physical simulator or solver. Using a local sampling strategy, we achieve to reduce the intrinsic high dimensionality of the design space and improve the training accuracy and the scalability of the SDL-TO framework. The method is demonstrated by benchmark examples and AM materials design for heat conduction. The proposed SDL-TO framework shows competitive performance compared to the baseline methods but significantly reduces the computational cost by a speed up of around 8.6x over the standard TO implementation.

Bi, Sirui↗
DOE OSTI2022

Topology Optimization for Porous Electrodes

This code is for the topology optimization of porous electrodes. It was used to produce the results in Roy, T., Salazar de Troya, M.A., Worsley, M.A. and Beck, V.A., 2021. Topology optimization for the design of porous electrodes. arXiv preprint arXiv:2111.12059.

Roy, Thomas↗
DOE OSTI2017

Topology optimization under uncertainty via non-intrusive polynomial chaos expansion

This paper presents a systematic approach for topology optimization under uncertainty that integrates non-intrusive polynomial chaos expansion with design sensitivity analysis for reliability-based and robust topology optimization. Uncertainty is introduced in loading and in geometry to address the manufacturing variability. The manufacturing variability is modeled via a thresholding technique in which the threshold field is represented by a reduced dimensional random field. Response metrics such as compliance and volume are characterized as polynomial chaos expansions of the underlying uncertain parameters thus allowing accurate and efficient estimation of statistical moments, failure probabilities and their sensitivities. The number of simulations is reduced for linear structures under loading uncertainty by means of superposition. Efficiency of the non-intrusive polynomial chaos approach is highlighted by comparison with the Monte Carlo method in terms of the number of simulations. To demonstrate the effect of uncertainty, optimized designs that consider uncertainty are compared to those that do not. Finally, comparisons of polynomial chaos expansion to existing analytical methods on a benchmark numerical example are also provided for reliability-based and worst case designs.

42 ENGINEERING↗
DOE OSTI2018

Multiscale topology optimization using neural network surrogate models

In this study, we are concerned with optimization of macroscale elastic structures that are designed utilizing spatially varying microscale metamaterials. The macroscale optimization is accomplished using gradient-based nonlinear topological optimization. But instead of using density as the optimization decision variable, the decision variables are the multiple parameters that define the local microscale metamaterial. This is accomplished using single layer feedforward Gaussian basis function networks as a surrogate models of the elastic response of the microscale metamaterial. The surrogate models are trained using highly resolved continuum finite element simulations of the microscale metamaterials and hence are significantly more accurate than analytical models e.g. classical beam theory. Because the derivative of the surrogate model is important for sensitivity analysis of the macroscale topology optimization, a neural network training procedure based on the Sobolev norm is described. Since the SIMP method is not appropriate for spatially varying lattices, an alternative method is developed to enable creation of void regions. Lastly, the efficacy of this approach is demonstrated via several examples in which the optimal graded metamaterial outperforms a traditional solid structure.

42 ENGINEERING↗
DOE OSTI2021

Topology optimization of additively manufactured fluidic components free of internal support structures

This report integrates projection-based approaches for implementing overhang constraints with fluid topology optimization to design additively manufactured fluidic components that do not require internal support structures. Internal support structures are challenging, potentially impossible to remove in complex fluid networks, yet would degrade fluidic performance if left within the part. This presents a major challenge in coupling topology optimization with additive manufacturing in the design of fluid components. The proposed approach leverages past work in overhang constraints for solid mechanics, including projection formulations and adjoint sensitivity analysis, and considers incompressible Navier–Stokes equations for laminar fluid flow. The approach is demonstrated on 2D and 3D fluid topology optimization problems to minimize pressure drop and constrain mass flow rates in pipes and manifolds. Resulting designs are crisp, logical, satisfy performance constraints, and satisfy overhang constraints, eliminating the need for internal support structures.

42 ENGINEERING↗