Isogeometric shape optimisation of shell structures using multiresolution subdivision surfaces

We introduce the isogeometric shape optimisation of thin shell structures using subdivision surfaces. Both triangular Loop and quadrilateral Catmull-Clark subdivision schemes are considered for geometry modelling and finite element analysis. A gradient-based shape optimisation technique is implemented to minimise compliance, i.e. to maximise stiffness. Different control meshes describing the same surface are used for geometry representation, optimisation and finite element analysis. The finite element analysis is performed with subdivision basis functions corresponding to a sufficiently refined control mesh. During iterative shape optimisation the geometry is updated starting from the coarsest control mesh and proceeding to increasingly finer control meshes. This multiresolution approach provides a means for regularising the optimisation problem and prevents the appearance of sub-optimal jagged geometries with fine-scale oscillations. The finest control mesh for optimisation is chosen in accordance with the desired smallest feature size in the optimised geometry. The proposed approach is applied to three optimisation examples, namely a catenary, a roof over a rectangular domain and a freeform architectural shell roof. The influence of the geometry description and the used subdivision scheme on the obtained optimised curved geometries are investigated in detail

Isogeometric FEM-BEM coupled structural-acoustic analysis of shells using subdivision surfaces

We introduce a coupled finite and boundary element formulation for acoustic scattering analysis over thin shell structures. A triangular Loop subdivision surface discretisation is used for both geometry and analysis fields. The Kirchhoff-Love shell equation is discretised with the finite element method and the Helmholtz equation for the acoustic field with the boundary element method. The use of the boundary element formulation allows the elegant handling of infinite domains and precludes the need for volumetric meshing. In the present work the subdivision control meshes for the shell displacements and the acoustic pressures have the same resolution. The corresponding smooth subdivision basis functions have the $C^1$ continuity property required for the Kirchhoff-Love formulation and are highly efficient for the acoustic field computations. We validate the proposed isogeometric formulation through a closed-form solution of acoustic scattering over a thin shell sphere. Furthermore, we demonstrate the ability of the proposed approach to handle complex geometries with arbitrary topology that provides an integrated isogeometric design and analysis workflow for coupled structural-acoustic analysis of shells

Boundary element based multiresolution shape optimisation in electrostatics

We consider the shape optimisation of high-voltage devices subject to electrostatic field equations by combining fast boundary elements with multiresolution subdivision surfaces. The geometry of the domain is described with subdivision surfaces and different resolutions of the same geometry are used for optimisation and analysis. The primal and adjoint problems are discretised with the boundary element method using a sufficiently fine control mesh. For shape optimisation the geometry is updated starting from the coarsest control mesh with increasingly finer control meshes. The multiresolution approach effectively prevents the appearance of non-physical geometry oscillations in the optimised shapes. Moreover, there is no need for mesh regeneration or smoothing during the optimisation due to the absence of a volume mesh. We present several numerical experiments and one industrial application to demonstrate the robustness and versatility of the developed approach.Web of Science29759858

Boundary element based multiresolution shape optimisation in electrostatics

We consider the shape optimisation of high-voltage devices subject to electrostatic field equations by combining fast boundary elements with multiresolution subdivision surfaces. The geometry of the domain is described with subdivision surfaces and different resolutions of the same geometry are used for optimisation and analysis. The primal and adjoint problems are discretised with the boundary element method using a sufficiently fine control mesh. For shape optimisation the geometry is updated starting from the coarsest control mesh with increasingly finer control meshes. The multiresolution approach effectively prevents the appearance of non-physical geometry oscillations in the optimised shapes. Moreover, there is no need for mesh regeneration or smoothing during the optimisation due to the absence of a volume mesh. We present several numerical experiments and one industrial application to demonstrate the robustness and versatility of the developed approach.We gratefully acknowledge the support provided by the EU commission through the FP7 Marie Curie IAPP project CASOPT (PIAP-GA-2008-230224). K.B. and F.C. thank for the additional support provided by EPSRC through #EP/G008531/1. J.Z. thanks for the support provided by the European Regional Development Fund in the IT4Innovations Centre of Excellence project (CZ.1.05/1.1.00/02.0070) and by the project SPOMECH – Creating a Multidisciplinary R&D Team for Reliable Solution of Mechanical Problems, reg. no. CZ.1.07/2.3.00/20.0070 within the Operational Programme ‘Education for Competitiveness’ funded by the Structural Funds of the European Union and the state budget of the Czech Republic. Special thanks to Andreas Blaszczyk from the ABB Corporate Research Center Switzerland for fruitful discussions and for providing the industrial applications.This is the final version of the article. It first appeared from Elsevier via http://dx.doi.org/10.1016/j.jcp.2015.05.01

Infill topology and shape optimisation of lattice-skin structures

Lattice-skin structures composed of a thin-shell skin and a lattice infill are widespread in nature and large-scale engineering due to their efficiency and exceptional mechanical properties. Recent advances in additive manufacturing, or 3D printing, make it possible to create lattice-skin structures of almost any size with arbitrary shape and geometric complexity. We propose a novel gradient-based approach to optimising both the shape and infill of lattice-skin structures to improve their efficiency further. The respective gradients are computed by fully considering the lattice-skin coupling while the lattice topology and shape optimisation problems are solved in a sequential manner. The shell is modelled as a Kirchhoff-Love shell and analysed using isogeometric subdivision surfaces, whereas the lattice is modelled as a pin-jointed truss. The lattice consists of many cells, possibly of different sizes, with each containing a small number of struts. We propose a penalisation approach akin to the SIMP (solid isotropic material with penalisation) method for topology optimisation of the lattice. Furthermore, a corresponding sensitivity filter and a lattice extraction technique are introduced to ensure the stability of the optimisation process and to eliminate scattered struts of small cross-sectional areas. The developed topology optimisation technique is suitable for non-periodic, non-uniform lattices. For shape optimisation of both the shell and the lattice, the geometry of the lattice-skin structure is parameterised using the free-form deformation technique. The topology and shape optimisation problems are solved in an iterative, sequential manner. The effectiveness of the proposed approach and the influence of different algorithmic parameters are demonstrated with several numerical examples.Comment: 20 pages, 17 figure

Isogeometric FEM-BEM coupled structural-acoustic analysis of shells using subdivision surfaces

We introduce a coupled finite and boundary element formulation for acoustic scattering analysis over thin shell structures. A triangular Loop subdivision surface discretisation is used for both geometry and analysis fields. The Kirchhoff-Love shell equation is discretised with the finite element method and the Helmholtz equation for the acoustic field with the boundary element method. The use of the boundary element formulation allows the elegant handling of infinite domains and precludes the need for volumetric meshing. In the present work the subdivision control meshes for the shell displacements and the acoustic pressures have the same resolution. The corresponding smooth subdivision basis functions have the $C^1$ continuity property required for the Kirchhoff-Love formulation and are highly efficient for the acoustic field computations. We validate the proposed isogeometric formulation through a closed-form solution of acoustic scattering over a thin shell sphere. Furthermore, we demonstrate the ability of the proposed approach to handle complex geometries with arbitrary topology that provides an integrated isogeometric design and analysis workflow for coupled structural-acoustic analysis of shells

Topologically robust CAD model generation for structural optimisation

Computer-aided design (CAD) models play a crucial role in the design, manufacturing and maintenance of products. Therefore, the mesh-based finite element descriptions common in structural optimisation must be first translated into CAD models. Currently, this can at best be performed semi-manually. We propose a fully automated and topologically accurate approach to synthesise a structurally-sound parametric CAD model from topology optimised finite element models. Our solution is to first convert the topology optimised structure into a spatial frame structure and then to regenerate it in a CAD system using standard constructive solid geometry (CSG) operations. The obtained parametric CAD models are compact, that is, have as few as possible geometric parameters, which makes them ideal for editing and further processing within a CAD system. The critical task of converting the topology optimised structure into an optimal spatial frame structure is accomplished in several steps. We first generate from the topology optimised voxel model a one-voxel-wide voxel chain model using a topology-preserving skeletonisation algorithm from digital topology. The weighted undirected graph defined by the voxel chain model yields a spatial frame structure after processing it with standard graph algorithms. Subsequently, we optimise the cross-sections and layout of the frame members to recover its optimality, which may have been compromised during the conversion process. At last, we generate the obtained frame structure in a CAD system by repeatedly combining primitive solids, like cylinders and spheres, using boolean operations. The resulting solid model is a boundary representation (B-Rep) consisting of trimmed non-uniform rational B-spline (NURBS) curves and surfaces