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

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

Research on inverse, hybrid and optimization problems in engineering sciences with emphasis on turbomachine aerodynamics: Review of Chinese advances

Advances in inverse design and optimization theory in engineering fields in China are presented. Two original approaches, the image-space approach and the variational approach, are discussed in terms of turbomachine aerodynamic inverse design. Other areas of research in turbomachine aerodynamic inverse design include the improved mean-streamline (stream surface) method and optimization theory based on optimal control. Among the additional engineering fields discussed are the following: the inverse problem of heat conduction, free-surface flow, variational cogeneration of optimal grid and flow field, and optimal meshing theory of gears

The collapse of the local, Spitzer-Haerm formulation and a global-local generalization for heat flow in an inhomogeneous, fully ionized plasma

The breakdown of the classical (CBES) field aligned transport relations for electrons in an inhomogeneous, fully ionized plasma as a mathematical issue of radius of convergence is addressed, the finite Knudsen number conditions when CBES results are accurate is presented and a global-local (GL) way to describe the results of Coulomb physics moderated conduction that is more nearly appropriate for astrophysical plasmas are defined. This paper shows the relationship to and points of departure of the present work from the CBES approach. The CBES heat law in current use is shown to be an especially restrictive special case of the new, more general GL result. A preliminary evaluation of the dimensionless heat function, using analytic formulas, shows that the dimensionless heat function profiles versus density of the type necessary for a conduction supported high speed solar wind appear possible

A Method for Geometry Optimization in a Simple Model of Two-Dimensional Heat Transfer

This investigation is motivated by the problem of optimal design of cooling elements in modern battery systems. We consider a simple model of two-dimensional steady-state heat conduction described by elliptic partial differential equations and involving a one-dimensional cooling element represented by a contour on which interface boundary conditions are specified. The problem consists in finding an optimal shape of the cooling element which will ensure that the solution in a given region is close (in the least squares sense) to some prescribed target distribution. We formulate this problem as PDE-constrained optimization and the locally optimal contour shapes are found using a gradient-based descent algorithm in which the Sobolev shape gradients are obtained using methods of the shape-differential calculus. The main novelty of this work is an accurate and efficient approach to the evaluation of the shape gradients based on a boundary-integral formulation which exploits certain analytical properties of the solution and does not require grids adapted to the contour. This approach is thoroughly validated and optimization results obtained in different test problems exhibit nontrivial shapes of the computed optimal contours.Comment: Accepted for publication in "SIAM Journal on Scientific Computing" (31 pages, 9 figures

Analysis of coupled heat and moisture transfer in masonry structures

Evaluation of effective or macroscopic coefficients of thermal conductivity under coupled heat and moisture transfer is presented. The paper first gives a detailed summary on the solution of a simple steady state heat conduction problem with an emphasis on various types of boundary conditions applied to the representative volume element -- a periodic unit cell. Since the results essentially suggest no superiority of any type of boundary conditions, the paper proceeds with the coupled nonlinear heat and moisture problem subjecting the selected representative volume element to the prescribed macroscopically uniform heat flux. This allows for a direct use of the academic or commercially available codes. Here, the presented results are derived with the help of the SIFEL (SIimple Finite Elements) system.Comment: 23 pages, 11 figure