State-of-the-art in aerodynamic shape optimisation methods

Aerodynamic optimisation has become an indispensable component for any aerodynamic design over the past 60 years, with applications to aircraft, cars, trains, bridges, wind turbines, internal pipe flows, and cavities, among others, and is thus relevant in many facets of technology. With advancements in computational power, automated design optimisation procedures have become more competent, however, there is an ambiguity and bias throughout the literature with regards to relative performance of optimisation architectures and employed algorithms. This paper provides a well-balanced critical review of the dominant optimisation approaches that have been integrated with aerodynamic theory for the purpose of shape optimisation. A total of 229 papers, published in more than 120 journals and conference proceedings, have been classified into 6 different optimisation algorithm approaches. The material cited includes some of the most well-established authors and publications in the field of aerodynamic optimisation. This paper aims to eliminate bias toward certain algorithms by analysing the limitations, drawbacks, and the benefits of the most utilised optimisation approaches. This review provides comprehensive but straightforward insight for non-specialists and reference detailing the current state for specialist practitioners

Curve Skeleton and Moments of Area Supported Beam Parametrization in Multi-Objective Compliance Structural Optimization

This work addresses the end-to-end virtual automation of structural optimization up to the derivation of a parametric geometry model that can be used for application areas such as additive manufacturing or the verification of the structural optimization result with the finite element method. A holistic design in structural optimization can be achieved with the weighted sum method, which can be automatically parameterized with curve skeletonization and cross-section regression to virtually verify the result and control the local size for additive manufacturing. is investigated in general. In this paper, a holistic design is understood as a design that considers various compliances as an objective function. This parameterization uses the automated determination of beam parameters by so-called curve skeletonization with subsequent cross-section shape parameter estimation based on moments of area, especially for multi-objective optimized shapes. An essential contribution is the linking of the parameterization with the results of the structural optimization, e.g., to include properties such as boundary conditions, load conditions, sensitivities or even density variables in the curve skeleton parameterization. The parameterization focuses on guiding the skeletonization based on the information provided by the optimization and the finite element model. In addition, the cross-section detection considers circular, elliptical, and tensor product spline cross-sections that can be applied to various shape descriptors such as convolutional surfaces, subdivision surfaces, or constructive solid geometry. The shape parameters of these cross-sections are estimated using stiffness distributions, moments of area of 2D images, and convolutional neural networks with a tailored loss function to moments of area. Each final geometry is designed by extruding the cross-section along the appropriate curve segment of the beam and joining it to other beams by using only unification operations. The focus of multi-objective structural optimization considering 1D, 2D and 3D elements is on cases that can be modeled using equations by the Poisson equation and linear elasticity. This enables the development of designs in application areas such as thermal conduction, electrostatics, magnetostatics, potential flow, linear elasticity and diffusion, which can be optimized in combination or individually. Due to the simplicity of the cases defined by the Poisson equation, no experts are required, so that many conceptual designs can be generated and reconstructed by ordinary users with little effort. Specifically for 1D elements, a element stiffness matrices for tensor product spline cross-sections are derived, which can be used to optimize a variety of lattice structures and automatically convert them into free-form surfaces. For 2D elements, non-local trigonometric interpolation functions are used, which should significantly increase interpretability of the density distribution. To further improve the optimization, a parameter-free mesh deformation is embedded so that the compliances can be further reduced by locally shifting the node positions. Finally, the proposed end-to-end optimization and parameterization is applied to verify a linear elasto-static optimization result for and to satisfy local size constraint for the manufacturing with selective laser melting of a heat transfer optimization result for a heat sink of a CPU. For the elasto-static case, the parameterization is adjusted until a certain criterion (displacement) is satisfied, while for the heat transfer case, the manufacturing constraints are satisfied by automatically changing the local size with the proposed parameterization. This heat sink is then manufactured without manual adjustment and experimentally validated to limit the temperature of a CPU to a certain level.:TABLE OF CONTENT III I LIST OF ABBREVIATIONS V II LIST OF SYMBOLS V III LIST OF FIGURES XIII IV LIST OF TABLES XVIII 1. INTRODUCTION 1 1.1 RESEARCH DESIGN AND MOTIVATION 6 1.2 RESEARCH THESES AND CHAPTER OVERVIEW 9 2. PRELIMINARIES OF TOPOLOGY OPTIMIZATION 12 2.1 MATERIAL INTERPOLATION 16 2.2 TOPOLOGY OPTIMIZATION WITH PARAMETER-FREE SHAPE OPTIMIZATION 17 2.3 MULTI-OBJECTIVE TOPOLOGY OPTIMIZATION WITH THE WEIGHTED SUM METHOD 18 3. SIMULTANEOUS SIZE, TOPOLOGY AND PARAMETER-FREE SHAPE OPTIMIZATION OF WIREFRAMES WITH B-SPLINE CROSS-SECTIONS 21 3.1 FUNDAMENTALS IN WIREFRAME OPTIMIZATION 22 3.2 SIZE AND TOPOLOGY OPTIMIZATION WITH PERIODIC B-SPLINE CROSS-SECTIONS 27 3.3 PARAMETER-FREE SHAPE OPTIMIZATION EMBEDDED IN SIZE OPTIMIZATION 32 3.4 WEIGHTED SUM SIZE AND TOPOLOGY OPTIMIZATION 36 3.5 CROSS-SECTION COMPARISON 39 4. NON-LOCAL TRIGONOMETRIC INTERPOLATION IN TOPOLOGY OPTIMIZATION 41 4.1 FUNDAMENTALS IN MATERIAL INTERPOLATIONS 43 4.2 NON-LOCAL TRIGONOMETRIC SHAPE FUNCTIONS 45 4.3 NON-LOCAL PARAMETER-FREE SHAPE OPTIMIZATION WITH TRIGONOMETRIC SHAPE FUNCTIONS 49 4.4 NON-LOCAL AND PARAMETER-FREE MULTI-OBJECTIVE TOPOLOGY OPTIMIZATION 54 5. FUNDAMENTALS IN SKELETON GUIDED SHAPE PARAMETRIZATION IN TOPOLOGY OPTIMIZATION 58 5.1 SKELETONIZATION IN TOPOLOGY OPTIMIZATION 61 5.2 CROSS-SECTION RECOGNITION FOR IMAGES 66 5.3 SUBDIVISION SURFACES 67 5.4 CONVOLUTIONAL SURFACES WITH META BALL KERNEL 71 5.5 CONSTRUCTIVE SOLID GEOMETRY 73 6. CURVE SKELETON GUIDED BEAM PARAMETRIZATION OF TOPOLOGY OPTIMIZATION RESULTS 75 6.1 FUNDAMENTALS IN SKELETON SUPPORTED RECONSTRUCTION 76 6.2 SUBDIVISION SURFACE PARAMETRIZATION WITH PERIODIC B-SPLINE CROSS-SECTIONS 78 6.3 CURVE SKELETONIZATION TAILORED TO TOPOLOGY OPTIMIZATION WITH PRE-PROCESSING 82 6.4 SURFACE RECONSTRUCTION USING LOCAL STIFFNESS DISTRIBUTION 86 7. CROSS-SECTION SHAPE PARAMETRIZATION FOR PERIODIC B-SPLINES 96 7.1 PRELIMINARIES IN B-SPLINE CONTROL GRID ESTIMATION 97 7.2 CROSS-SECTION EXTRACTION OF 2D IMAGES 101 7.3 TENSOR SPLINE PARAMETRIZATION WITH MOMENTS OF AREA 105 7.4 B-SPLINE PARAMETRIZATION WITH MOMENTS OF AREA GUIDED CONVOLUTIONAL NEURAL NETWORK 110 8. FULLY AUTOMATED COMPLIANCE OPTIMIZATION AND CURVE-SKELETON PARAMETRIZATION FOR A CPU HEAT SINK WITH SIZE CONTROL FOR SLM 115 8.1 AUTOMATED 1D THERMAL COMPLIANCE MINIMIZATION, CONSTRAINED SURFACE RECONSTRUCTION AND ADDITIVE MANUFACTURING 118 8.2 AUTOMATED 2D THERMAL COMPLIANCE MINIMIZATION, CONSTRAINT SURFACE RECONSTRUCTION AND ADDITIVE MANUFACTURING 120 8.3 USING THE HEAT SINK PROTOTYPES COOLING A CPU 123 9. CONCLUSION 127 10. OUTLOOK 131 LITERATURE 133 APPENDIX 147 A PREVIOUS STUDIES 147 B CROSS-SECTION PROPERTIES 149 C CASE STUDIES FOR THE CROSS-SECTION PARAMETRIZATION 155 D EXPERIMENTAL SETUP 15

Optimal Design of Functionally Graded Parts

Several additive manufacturing processes are capable of fabricating three-dimensional parts with complex distribution of material composition to achieve desired local properties and functions. This unique advantage could be exploited by developing and implementing methodologies capable of optimizing the distribution of material composition for one-, two-, and three-dimensional parts. This paper is the first effort to review the research works on developing these methods. The underlying components (i.e., building blocks) in all of these methods include the homogenization approach, material representation technique, finite element analysis approach, and the choice of optimization algorithm. The overall performance of each method mainly depends on these components and how they work together. For instance, if a simple one-dimensional analytical equation is used to represent the material composition distribution, the finite element analysis and optimization would be straightforward, but it does not have the versatility of a method which uses an advanced representation technique. In this paper, evolution of these methods is followed; noteworthy homogenization approaches, representation techniques, finite element analysis approaches, and optimization algorithms used/developed in these studies are described; and most powerful design methods are identified, explained, and compared against each other. Also, manufacturing techniques, capable of producing functionally graded materials with complex material distribution, are reviewed; and future research directions are discussed

Evolutionary structural pptimisation based on boundary element representation of b-spline geometry

Evolutionary Structural Optimisation (ESO) has become a well-established technique for determining the optimum shape and topology of a structure given a set of loads and constraints. The basic ESO concept that the optimum topology design evolves by slow removal and addition of material has matured over the last ten years. Nevertheless, the development of the method has almost exclusively considered finite elements (FE) as the approach for providing stress solutions. This thesis presents an ESO approach based on the boundary element method. Non-uniform rational B-splines (NURBS) are used to define the geometry of the component and, since the shape of these splines is governed by a set of control points, use can be made of the locations of these control points as design variables. The developed algorithm creates internal cavities to accomplish topology changes. Cavities are also described by NURBS and so they have similar behaviour to the outside boundary. Therefore, both outside and inside are optimised at the same time. The optimum topologies evolve allowing cavities to merge between each other and to their closest outer boundary. Two-dimensional structural optimisation is investigated in detail exploring multi-load case and multi-criteria optimisation. The algorithm is also extended to three-dimensional optimisation, in which promising preliminary results are obtained. It is shown that this approach overcomes some of the drawbacks inherent in traditional FE-based approaches, and naturally provides accurate stress solutions on smooth boundary representations at each iteration

TOPOLOGY OPTIMIZATION USING A LEVEL SET PENALIZATION WITH CONSTRAINED TOPOLOGY FEATURES

Topology optimization techniques have been applied to structural design problems in order to determine the best material distribution in a given domain. The topology optimization problem is ill-posed because optimal designs tend to have infinite number of holes. In order to regularize this problem, a geometrical constraint, for instance the perimeter of the design (i.e., the measure of the boundary of the solid region, length in 2D problems or the surface area in 3D problems) is usually imposed. In this thesis, a novel methodology to solve the topology optimization problem with a constraint on the number of holes is proposed. Case studies are performed and numerical tests evaluated as a way to establish the efficacy and reliability of the proposed method. In the proposed topology optimization process, the material/void distribution evolves towards the optimum in an iterative process in which discretization is performed by finite elements and the material densities in each element are considered as the design variables. In this process, the material/void distribution is updated by a two-step procedure. In the first step, a temporary density function, ϕ*(x), is updated through the steepest descent direction. In the subsequent step, the temporary density function ϕ*(x) is used to model the next material/void distribution, χ*(x), by means of the level set concept. With this procedure, holes are easily created and quantified, material is conveniently added/removed. If the design space is reduced to the elements in the boundary, the topology optimization process turns into a shape optimization procedure in which the boundaries are allowed to move towards the optimal configuration. Thus, the methodology proposed in this work controls the number of holes in the optimal design by combining both topology and shape optimization. In order to evaluate the effectiveness of the proposed method, 2-D minimum compliance problems with volume constraints are solved and numerical tests performed. In addition, the method is capable of handling very general objective functions, and the sensitivities with respect to the design variables can be conveniently computed

Heuristics and metaheuristics in the design of sound-absorbing porous materials

Inexact optimisation techniques such as heuristics and metaheuristics that quickly find near-optimal solutions are widely used to solve hard problems. While metaheuristics are well studied on specific problem domains such as travelling salesman, timetabling, vehicle routing etc., their extension to engineering domains is largely unexplored due to the requirement of domain expertise. In this thesis, we address a specific engineering domain: the design of sound-absorbing porous materials. Porous materials are foams, fibrous materials, woven and non-woven textiles, etc., that are widely used in automotive, aerospace and household applications to isolate and absorb noise to prevent equipment damage, protect hearing or ensure comfort. These materials constitute a significant amount of dead weight in aircraft and space applications, and choosing sub-optimal designs would lead to inefficiency and increased costs. By carefully choosing the material properties and shapes of these materials, favourable resonances can be created making it possible to improve absorption while also reducing weight. The optimisation problem structure is yet to be well-explored and not many comparison studies are available in this domain. This thesis aims to address the knowledge gap by analysing the performance of existing and novel heuristic and metaheuristic methods. Initially, the problem structure is explored by considering a one-dimensional layered sound package problem. Then, the challenging two-dimensional foam shape and topology optimisation is addressed. Topology optimisation involves optimally distributing a given volume of material in a design region such that a performance measure is maximised. Although extensive studies exist for the compliance minimisation problem domain, studies and comparisons on porous material problems are relatively rare. Firstly, a single objective absorption maximisation problem with a constraint on the weight is considered. Then a multi-objective problem of simultaneously maximising absorption and minimising weight is considered. The unique nature of the topology optimisation problem allows it to be solved using combinatorial or continuous, gradient or non-gradient methods. In this work, several optimisation methods are studied, including solid isotropic material with penalisation (SIMP), hill climbing, constructive heuristics, genetic algorithms, tabu search, co-variance matrix adaptation evolution strategy (CMA-ES), differential evolution, non-dominated sorting genetic algorithm (NSGA-II) and hybrid strategies. These approaches are tested on a benchmark of seven acoustics problem instances. The results are used to extract domain-specific insights. The findings highlight that the problem domain is rich with unique varieties of solutions, and by using domain-specific insights, one can design hybrid gradient and non-gradient methods that consistently outperform state-of-the-art ones