Layout optimization for multi-bi-modulus materials system under multiple load cases

Financial support from the National Natural Science Foundation of China (Grant No. 51179164) and the Australian Research Council (Grant No. DP140103137) is acknowledged

Design and Topology Optimisation of Tissue Scaffolds

Tissue restoration by tissue scaffolding is an emerging technique with many potential applications. While it is well-known that the structural properties of tissue scaffolds play a critical role in cell regrowth, it is usually unclear how optimal tissue regeneration can be achieved. This thesis hereby presents a computational investigation of tissue scaffold design and optimisation. This study proposes an isosurface-based characterisation and optimisation technique for the design of microscopic architecture, and a porosity-based approach for the design of macroscopic structure. The goal of this study is to physically define the optimal tissue scaffold construct, and to establish any link between cell viability and scaffold architecture. Single-objective and multi-objective topology optimisation was conducted at both microscopic and macroscopic scales to determine the ideal scaffold design. A high quality isosurface modelling technique was formulated and automated to define the microstructure in stereolithography format. Periodic structures with maximised permeability, and theoretically maximum diffusivity and bulk modulus were found using a modified level set method. Microstructures with specific effective diffusivity were also created by means of inverse homogenisation. Cell viability simulation was subsequently conducted to show that the optimised microstructures offered a more viable environment than those with random microstructure. The cell proliferation outcome in terms of cell number and survival rate was also improved through the optimisation of the macroscopic porosity profile. Additionally artificial vascular systems were created and optimised to enhance diffusive nutrient transport. The formation of vasculature in the optimisation process suggests that natural vascular systems acquire their fractal shapes through self-optimisation

Design and Topology Optimisation of Tissue Scaffolds

Tissue restoration by tissue scaffolding is an emerging technique with many potential applications. While it is well-known that the structural properties of tissue scaffolds play a critical role in cell regrowth, it is usually unclear how optimal tissue regeneration can be achieved. This thesis hereby presents a computational investigation of tissue scaffold design and optimisation. This study proposes an isosurface-based characterisation and optimisation technique for the design of microscopic architecture, and a porosity-based approach for the design of macroscopic structure. The goal of this study is to physically define the optimal tissue scaffold construct, and to establish any link between cell viability and scaffold architecture. Single-objective and multi-objective topology optimisation was conducted at both microscopic and macroscopic scales to determine the ideal scaffold design. A high quality isosurface modelling technique was formulated and automated to define the microstructure in stereolithography format. Periodic structures with maximised permeability, and theoretically maximum diffusivity and bulk modulus were found using a modified level set method. Microstructures with specific effective diffusivity were also created by means of inverse homogenisation. Cell viability simulation was subsequently conducted to show that the optimised microstructures offered a more viable environment than those with random microstructure. The cell proliferation outcome in terms of cell number and survival rate was also improved through the optimisation of the macroscopic porosity profile. Additionally artificial vascular systems were created and optimised to enhance diffusive nutrient transport. The formation of vasculature in the optimisation process suggests that natural vascular systems acquire their fractal shapes through self-optimisation

Evolutionary structural optimisation as a robust and reliable design tool

Evolutionary Structural Optimisation (ESO) is a relatively new design tool used to improve and optimise the design of structures. It is a heuristic method where a few elements of an initial design domain of finite elements are iteratively removed. Such a process is carried out repeatedly until an optimum design is achieved, or until a desired given area or volume is reached. There have been many contributions to the ESO procedure since its conception back in 1992. For example, a provision known as Bi-Directional ESO (BESO) has now been incorporated where elements may not only be removed, but added. Also, rather than deal with elements where they are either present or not, the designer now has the option to change the element's properties in a progressive fashion. This includes the modulus of elasticity, the density of the material and the thickness of plate elements, and is known as Morphing ESO. In addition to the algorithmic aspects of ESO, a large preference exists to optimise a structure based on a selection of criteria for various physical processes. Such examples include stress minimisation, buckling and electromagnetic problems. In a changing world that demands the enhancement of design tools and methods that incorporate optimisation, the development of methods like ESO to accommodate this demand is called for. It is this demand that this thesis seeks to satisfy. This thesis develops and examines the concept of multicriteria optimisation in the ESO process. Taking into account the optimisation of numerous criteria simultaneously, Multicriteria ESO allows a more realistic and accurate approach to optimising a model in any given environment. Two traditional methods � the Weighting method and the Global Criterion (Min-max) method have been used, as has two unconventional methods � the Logical AND method and the Logical OR method. These four methods have been examined for different combinations of Finite Element Analysis (FEA) solver types. This has included linear static FEA solver, the natural frequency FEA solver and a recently developed inertia FE solver. Mean compliance minimisation (stiffness maximisation), frequency maximisation and moment of inertia maximisation are an assortment of the specific objectives incorporated. Such a study has provided a platform to use many other criteria and multiple combinations of criteria. In extending the features of ESO, and hence its practical capabilities as a design tool, the creation of another optimisation method based on ESO has been ushered in. This method concerns the betterment of the bending and rotational performance of cross-sectional areas and is known as Evolutionary Moment of Inertia Optimisation (EMIO). Again founded upon a domain of finite elements, the EMIO method seeks to either minimise or maximise the rectangular, product and polar moments of inertia. This dissertation then goes one step further to include the EMIO method as one of the objectives considered in Multicriteria ESO as mentioned above. Most structures, (if not all) in reality are not homogenous as assumed by many structural optimisation methods. In fact, many structures (particularly biological ones) are composed of different materials or the same material with continually varying properties. In this thesis, a new feature called Constant Width Layer (CWL) ESO is developed, in which a distinct layer of material evolves with the developing boundary. During the optimisation process, the width of the outer surrounding material remains constant and is defined by the user. Finally, in verifying its usefulness to the practical aspect of design, the work presented herein applies the CWL ESO and the ESO methods to two dental case studies. They concern the optimisation of an anterior (front of the mouth) ceramic dental bridge and the optimisation of a posterior (back of the mouth) ceramic dental bridge. Comparisons of these optimised models are then made to those developed by other methods

Simultaneous optimisation of structural topology and material grading using level set method

Peer reviewedPublisher PD

Revisiting topology optimization with buckling constraints

We review some features of topology optimization with a lower bound on the critical load factor, as computed by linearized buckling analysis. The change of the optimized design, the competition between stiffness and stability requirements and the activation of several buckling modes, depending on the value of such lower bound, are studied. We also discuss some specific issues which are of particular interest for this problem, as the use of non-conforming finite elements for the analysis, the use of inconsistent sensitivities in the optimization and the replacement of the single eigenvalue constraints with an aggregated measure. We discuss the influence of these practices on the optimization result, giving some recommendations.Comment: 15 pages, 12 figures, 2 table

Cluster-Based Optimization of Cellular Materials and Structures for Crashworthiness

The objective of this work is to establish a cluster-based optimization method for the optimal design of cellular materials and structures for crashworthiness, which involves the use of nonlinear, dynamic finite element models. The proposed method uses a cluster-based structural optimization approach consisting of four steps: conceptual design generation, clustering, metamodel-based global optimization, and cellular material design. The conceptual design is generated using structural optimization methods. K-means clustering is applied to the conceptual design to reduce the dimensional of the design space as well as define the internal architectures of the multimaterial structure. With reduced dimension space, global optimization aims to improve the crashworthiness of the structure can be performed efficiently. The cellular material design incorporates two homogenization methods, namely, energy-based homogenization for linear and nonlinear elastic material models and mean-field homogenization for (fully) nonlinear material models. The proposed methodology is demonstrated using three designs for crashworthiness that include linear, geometrically nonlinear, and nonlinear models

Topology optimisation for compliant hip implant design and reduced strain shielding

Stiff total hip arthroplasty implants can lead to strain shielding, bone loss and complex revision surgery. The aim of this study was to develop topology optimisation techniques for more compliant hip implant design. The Solid Isotropic Material with Penalisation (SIMP) method was adapted, and two hip stems were designed and additive manufactured: (1) a stem based on a stochastic porous structure, and (2) a selectively hollowed approach. Finite element analyses and experimental measurements were conducted to measure stem stiffness and predict the reduction in stress shielding. The selectively hollowed implant increased peri-implanted femur surface strains by up to 25 percentage points compared to a solid implant without compromising predicted strength. Despite the stark differences in design, the experimentally measured stiffness results were near identical for the two optimised stems, with 39% and 40% reductions in the equivalent stiffness for the porous and selectively hollowed implants, respectively, compared to the solid implant. The selectively hollowed implant’s internal structure had a striking resemblance to the trabecular bone structures found in the femur, hinting at intrinsic congruency between nature’s design process and topology optimisation. The developed topology optimisation process enables compliant hip implant design for more natural load transfer, reduced strain shielding and improved implant survivorship

Structural optimisation of random discontinuous fibre composites: Part 1 – Methodology

This paper presents a finite element model to optimise the fibre architecture of components manufactured from discontinuous fibre composites. An optimality criterion method has been developed to maximise global component stiffness, by determining optimum distributions for local section thickness and preform areal mass. The model is demonstrated by optimising the bending performance of a flat plate with three holes. Results are presented from a sensitivity study to highlight the level of compromise in stiffness optimisation caused by manufacturing constraints associated with the fibre deposition method, such as the scale of component features relative to the fibre length