Bendsøe and

Topology Optimization in Aerospace Kikuchi (1988)

Topology Optimization ? ?
State-of-the-Art and Future Perspectives

Ole Sigmund Design domain

TopOpt-Group (www.topopt.dtu.dk)
Dept. of Mechanical Engineering FE-Discretization
Technical University of Denmark (DTU)

Interpretation Optimal material redistribution

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Topology Optimization Applications Topology Optimization Applications

Small antennas

Automotive industry (Fabian Duddeck ) Acoustics

Wind turbines (SUZLON and FE-Design GmbH)
Cloaking

Energy harvesting
Extreme materials

Reconstructive surgery (Paulino/Sinn-Hanlon)

Micromachines (DTU Nanotech)
Nano-photonics Fluids Structural colours
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Applications in Architecture/Design Discrete topopt formulation

Mutsuro Sasaki : Qatar National Convention Centre

0/1 Integer problem

• Combinations: N=10, M=5 => 252
N! N=20, M=10 => 185.000
( N  M )! M !
N=40, M=20 => 1.4·109
N=100, M=50 => 1029

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

SIMP-approach Sensitivity analysis – adjoint method

Bendsøe (1989), Zhou and Rozvany (1991), Mlejnek (1992)

Objective function Equilibrium (FEM)

Stiffness interpolation:
Augmented
E objective function:

Differentiate:

1
 Collect U’ terms:

Adjoint problem:

Final sensitivity:

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 The Topology Optimization Process Regularization by low-pass filtering
Neighborhood:
Initialize FEM
R
Finite Element Analysis
(Elastic, Thermal, Electrical, etc.) Checkerboards
Sensitivity filtering (Sigmund 1997, Sigmund&Maute 2012)

Sensitivity Analysis

Regularization (filtering) Sensitivity analysis by adjoint method

Optimization
(material redistribution)
Density filtering (Bruns&Tortorelli/Bourdin 2001)
no Mesh refinement
ρe converged?
yes
Plot results
Mathematical Programming,
STOP Method of Moving Asymptotes (MMA) PDE-based filtering (Lazarov&Sigmund 2011)
by Svanberg (1987)

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

The ”TopOpt App” The ”TopOpt3d App”

The ”TopOpt App”: AppStore (iOS)

Google Play (Android)
Web-version: www.topopt.dtu.dk

Stats: November 2015: Stats: November 2015:

Android: 4900, iOS: 9000, web: 9700 See www.topopt.dtu.dk for more iOS: 2600, web: 730 (NB! Only, Appstore, iOS and PC – see www.topopt.dtu.dk)
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Århus Architect School,
TopOpt Rhino plugin Technion and DTU Public Codes
99 Line basic Matlab (Including FE, grad’s, OC)
OS, A 99 line topology optimization code written in MATLAB, SMO, 2001, 21, 120-127

88 line advanced Matlab (+advanced filters)

Andreassen, E.; Clausen, A.; Schevenels, M.; Lazarov, B. & OS, Efficient topology optimization in
MATLAB using 88 lines of code, SMO, 2011, 43, 1-16

On multigrid-CG for efficient topology optimization

Amir, O.; Aage, N. & Lazarov, B.S., SMO, 2014, 49, 815-829

Topology optimization using PETSc:

An easy-to-use, fully parallel, open-source topology optimization framework
Aage, N; Andreassen, E. & Lazarov, B.S., 2015, SMO, 51, 565-572

By Amir, Maier,
Søndergaard,
Aage, et al.
Freely downloadable from www.topopt.dtu.dk
Download at www.grasshopper3d.com/group/topopt (2000 downloads by December 2015)
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Challenges and goals

Methods
• Manufacturing limitations/uncertainties
• Feature control – advanced geometry control
Length-scale control and robustness
• Adaption to Additive Manufacturing (AM)
• Super large scale

Applications
• Extremal material design
• Non-linearities
• Multiphysics
• Wave propagation
• Multiscale

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Compliant mechanism design Projection method Guest et al (2004)

Filtering Projection

Sensitivity filtering Density filtering

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Local geometry control Robust formulation

Erosion
Sigmund (2007)

”Volume preserving”
Xu et al (2010)

Dilation
Guest et al (2004)

Sigmund, Acta Mechanica Sinica, 25, 227-239 (2009)

Wang, Lazarov and Sigmund, SMO, 43, 767-784 , (2011)
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Robust topopt formulation Robust electrostatic actuator design

Uniform over/under etching Over

etched

Blue print

Under
etched

Unique length scale control: c.f. Wang, Lazarov and Sigmund, SMO, (2011), Qian and Sigmund, CMAME, (2012) Qian and Sigmund, CMAME, (2012)
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Robust electrostatic actuator design

Ultra high resolution TopOpt

(overcoming the Duplo problem)

Qian and Sigmund, CMAME, (2012)

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Previous work in aircraft wing design Previous work in aircraft wing design
Stanford & Dunning, Journal of Aircraft, 2015, 52, 1298-1311:

“… the resulting structure typically bears no resemblance to traditional rib/spar

networks, which may indicate one of two things. The first is that the appropriate
physics, load cases, and/or constraint boundaries were not included in the
optimization problem, and if they had been, the resulting topology would qualitatively
approach a lattice of ribs and spars. The second is that the design problem was properly
defined, and that the non-traditional topology may present an interesting new
direction for efficient wing structures.”

Rao et al., JAST, 2009, 61, 402

Dunning et.al., AIAA, 2014

Stanford et al., JA, 2015, 52, 1298 Kenway et al., AIAA, 2014

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

+100M design variables +100M design variables

10

0.05

10
1

0.02

The code:
• PETSc based – highly scalable
• Solver: F-GMRES with MG preconditioner.
• Open source (topopt.dtu.dk)
• Includes filters, MMA, IO.
• Comes with minimum compliance example
• Aage; Andreassen & Lazarov, SMO, 2015, 51, 565-572
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 NASA Common Research Model Results: 135 million elements
Geometry and pressure load data from NASA:

Meshing by structured slices:

~1 billion elements (1216 x 256 x 3456)…

… largest element size ~ 8 mm
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Material with negative Poisson’s ratio

? ? ? ? ? ?

Input displacements
? ? ? ? ? ?
Material design and non-linearities ? ? ? ? ? ?
? ? ? ? ? ?
? ? ? ? ? ?
? ? ? ? ? ?

Output displacements

?
• FE on one cell with periodic B.C.
• Minimize Poisson’s ratio
• Constraint on bulk modulus and symmetry

Sigmund (1995)
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 3D Manufacturing and testing Negative thermal expansion coefficient

∆T
E1,  1
? E2 ,  2
Air

*  4.02
Andreassen, Lazarov & OS, MoM, 2014, 69, 1-10 Sigmund&Torquato, APL, 1996, 69, 3203-3205
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

3d negative thermal expansion Finite deformations

a
a

b b

Wang et al., J. Mech. Phys. Solids, 2014, 69, 156-174

Wang et al., CMAME, 2014, 276, 453-472
Produced by Erik Andreassen Clausen et al., Adv. Mater., 2015, 27(37), 5523-5527
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Manufacturing using Direct Ink Writing Design adapted to Direct Ink Writing

Air
Designs printed row- and
column-wise ⇒ Uniform features desired
Syringe
Ink

Nozzle

Ahn et al., JoVE 58 (2011)

Compton & Lewis, Adv. Mater. 26(34), 5930-5935 (2014) Clausen, Wang, et al., Adv. Mater. 27(37), 5523-5527 (2015)
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Uniform feature design using superellipses Optimized designs for  -0.8:0.2:0.8

Clausen, Wang, et al., Adv. Mater. 27(37), 5523-5527 (2015) Clausen, Wang, et al., Adv. Mater. 27(37), 5523-5527 (2015)
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 All designs printed row- and columnwise Complete set of realized designs

Scale bars: 5 mm

Clausen, Wang, et al., Adv. Mater. 27(37), 5523-5527 (2015) Clausen, Wang, et al., Adv. Mater. 27(37), 5523-5527 (2015)
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Deformation pattern for  = -0.8 Numerics vs experiments

0.8

0% 5% 10% 15% 20%

0.8

0% 5% 10% 15% 20%

Clausen, Wang, et al., Adv. Mater. 27(37), 5523-5527 (2015)

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Parameterization for any  [-0.8, 0.8] 3D Poisson’s ratio -0.8
Small deformation:

Average error
Finite deformation:

Poisson’s ratio ν

Clausen, Wang, et al., Adv. Mater. 27(37), 5523-5527 (2015) Wang et al., 2016, to be submitted
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Cooling fins for LED lamps

HYPERCOOL – Cool Danish Design

Thermofluidics

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Intuitive designs by industrial designer Thermofluidic equations

Incompressible Navier-Stokes equation for porous flow

Convection-diffusion equation

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Optimization of fluid mixing Natural convection cooler problem

cold

Mixing Crossing The chess board

cold

cold
hot

Andreasen; Gersborg & OS, IJNMF, 2009, 61, 498-513

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Natural convection cooler problem 3d results – temperature distribution
Gr=103 Gr=104
Gr

Gr=105 Gr=106

Alexandersen et al., IJNMF, 2014, 76, 699-721

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

3d results – velocity magnitude Conclusions

• TO is efficient in solving wide classes of engineering design

Gr=103 Gr=104 problems

• Here mostly concentrated on solids – lots of application in

fluids, thermofluidics, electromagnetics, nano-optics, etc.

• We are at the verge of being able to skip the post-processing

step and send TO results directly to (additive) manufacturing

• Still several interesting challenges:

Gr=105 Gr=106 • Large scale
• Non-linearities
• Multiphysics
• Multiscale
• Taking advantage of new manufacturing possibilties

Alexandersen, Sigmund and Aage, Submitted, 2015

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Further reading Localized random variations
TopOpt background
• OS & Maute, K., Topology optimization approaches: A comparative review, 2013, 48, 1031-1055
• OS, On the usefulness of non-gradient approaches in topology optimization, SMO, 2011, 43, 589-596
• Schevenels, Lazarov & OS, Robust TopOpt account. f. spat. varying man. err., CMAME, 2011, 200, 3613-3627
• Wang, Lazarov & OS, On projection methods, convergence and robust formulations in TopOpt, SMO, 2011,
43, 767-784
Codes
• Andreassen, E.; Clausen, A.; Schevenels, M.; Lazarov, B. & OS, Efficient TopOpt in MATLAB using 88 lines of
code, SMO, 2011, 43, 1-16
• Aage; Andreassen & Lazarov, B.S., TopOpt using PETSc: An easy-to-use, fully parallel, open-source topopt
framework, SMO, 2015, SMO, 51, 565-572
Material Design
• Andreassen, E.; Lazarov, B. & OS, Design of manuf. 3D extremal elastic microstr., MoM, 2014, 69, 1-10
• Wang, F.; OS & Jensen, J., Design of materials with prescribed nonlinear properties, JMPS, 2014, 69, 156-174
• Clausen; Wang; Jensen; OS & Lewis, Topology Optimized Architectures with Programmable Poisson's Ratio
over Large Deformations, Advanced Materials, 2015, 27, 5523-5527
Fluid Applications
• Andreasen, C. S.; Gersborg, A. R. & OS, TO of laminar fluid mixers, IJNMF, 2009, 61, 498-513
• Alexandersen, J.; Aage, N.; Andreasen, C. & OS, TO for natural convection probls, IJNMF, 2014, 76, 699-721

”TopOpt” App
See www.topopt.dtu.dk for more ”TopOpt3D” App
”TopOpt Game”
(iOS, Android,web)
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark

Probability-based topology optimization Probability-based topology optimization

Random geometry errors

Deterministic design Probabilistic design

Karhunen-Loeve expansion

MC
Stochastic collocation
Stochastic perturbation

Schevenels, Lazarov & Sigmund, CMAME, 2011, 200, 3613-3627 Schevenels, Lazarov & Sigmund, CMAME, 2011, 200, 3613-3627
Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark
 Smooth boundaries

Ole Sigmund, Mechanical Engineering, Solid Mechanics Technical University of Denmark