A Regularized Discrete Laminate Parametrization Technique with Applications to Wing-Box Design Optimization

Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/97055/1/AIAA2012-1519.pd

In-plane material filters for the discrete material optimization method

This paper presents in-plane material filters for the Discrete Material Optimization method used for optimizing laminated composite structures. The filters make it possible for engineers to specify a minimum length scale which governs the minimum size of areas with constant material continuity. Consequently, engineers can target the available production methods, and thereby increase its manufacturability while the optimizer is free to determine which material to apply together with an optimum location, shape, and size of these areas with constant material continuity. By doing so, engineers no longer have to group elements together in so-called patches, so to statically impose a minimum length scale. The proposed method imposes the minimum length scale through a standard density filter known from topology optimization of isotropic materials. This minimum length scale is generally referred to as the filter radius. However, the results show that the density filter alone gives designs with large measures of non-discreteness. In order to obtain near discrete designs an additional threshold projection filter is applied, so to push the physical design variables towards their discrete bounds. However, because the projection filter is a non-linear function of the design variables, the projected variables have to be re-scaled in a final so-called normalization filter. This is done to prevent the optimizer in creating superior, but non-physical pseudo-materials. The method is demonstrated on a series of minimum compliance examples together with a minimum mass example, and the results show that the method is indeed capable of imposing a minimum length scale onto the optimized layup

DMTO – a method for Discrete Material and Thickness Optimization of laminated composite structures

This paper presents a gradient based topology optimization method for Discrete Material and Thickness Optimization of laminated composite structures, labelled the DMTOmethod. The capabilities of the proposed method are demonstrated on mass minimization, subject to constraints on the structural criteria; buckling load factors, eigenfrequencies, and limited displacements. Furthermore, common design guidelines or rules, referred to as manufacturing constraints, are included explicitly in the optimization problem as series of linear inequalities. The material selection and thickness variation are optimized simultaneously through interpolation functions with penalization. Numerical results for several parameterizations of a finite element model of a generic main spar from a wind turbine blade arepresented. The different parameterizations represent different levels of complexity with respect to manufacturability. The results will thus give insight into the relation between potential weight saving and design complexity. The results show that the DMTO method is capable of solving the problems robustly with only few intermediate valued design variables.This paper presents a gradient based topology optimization method for Discrete Material and Thickness Optimization of laminated composite structures, labelled the DMTOmethod. The capabilities of the proposed method are demonstrated on mass minimization, subject to constraints on the structural criteria; buckling load factors, eigenfrequencies, and limited displacements. Furthermore, common design guidelines or rules, referred to as manufacturing constraints, are included explicitly in the optimization problem as series of linear inequalities. The material selection and thickness variation are optimized simultaneously through interpolation functions with penalization. Numerical results for several parameterizations of a finite element model of a generic main spar from a wind turbine blade arepresented. The different parameterizations represent different levels of complexity with respect to manufacturability. The results will thus give insight into the relation between potential weight saving and design complexity. The results show that the DMTO method is capable of solving the problems robustly with only few intermediate valued design variables.<br/

Thickness filters for gradient based multi-material and thickness optimization of laminated composite structures

This paper presents a new gradient based method for performing discrete material and thickness optimization of laminated composite structures. The novelty in the new method lies in the application of so-called casting constraints, or thickness filters in this context, to control the thickness variation throughout the laminate. The filters replace the layerwise density variables with a single continuous through-the-thickness design variable. Consequently, the filters eliminate the need for having explicit constraints for preventing intermediate void through the thickness of the laminate. Therefore, the filters reduce both the number of constraints and design variables in the optimization problem. Based upon a continuous approximation of a unit step function, the thickness filters are capable of projecting discrete 0/1 values to the underlying layerwise or ”physical” density variables which govern the presence of material in each layer through the thickness of the laminate. Combined with an in-plane density filter, the method enables manufacturers to control the length scale of the geometry while obtaining near discrete designs. Together with the applied manufacturing constraints it is now possible for manufacturers to steer the design towards a higher level of manufacturability. The method is demonstrated for mass minimization with displacement and manufacturing constraints. The results show that the method indeed is capable of obtaining near discrete designs which obey the governing constraints.</p