Structural topology optimization of multibody systems

Flexible multibody dynamics (FMD) has found many applications in control, analysis and design of mechanical systems. FMD together with the theory of structural optimization can be used for designing multibody systems with bodies which are lighter, but stronger. Topology optimization of static structures is an active research topic in structural mechanics. However, the extension to the dynamic case is less investigated as one has to face serious numerical difficulties. One way of extending static structural topology optimization to topology optimization of dynamic flexible multibody system with large rotational and transitional motion is investigated in this paper. The optimization can be performed simultaneously on all flexible bodies. The simulation part of optimization is based on an FEM approach together with modal reduction. The resulting nonlinear differential-algebraic systems are solved with the error controlled integrator IDA (Sundials) wrapped into Python environment by Assimulo [1]. A modified formulation of solid isometric material with penalization (SIMP) method is suggested to avoid numerical instabilities and convergence failures of the optimizer. Sensitivity analysis is central in structural optimization. The sensitivities are approximated to circumvent the expensive calculations. The provided examples show that the method is indeed suitable for optimizing a wide range of multibody systems. Standard SIMP method in structural topology optimization suggests stiffness penalization. To overcome the problem of instabilities and mesh distortion in the dynamic case we consider here additionally element mass penalization

System-Based Approaches for Structural Optimization of Flexible Mechanisms

peer reviewedThis paper reviews the state-of-the-art methods to perform structural optimization of flexible mechanisms. These methods are based on a system-based approach, i.e. the formulation of the design problem incorporates the time response of the mechanism that is obtained from a dynamic simulation of the flexible multibody system. The system-based approach aims at considering as precisely as possible the effects of nonlinear dynamic loading under various operating conditions. Also, the optimization process enhances most existing studies which are limited to (quasi-) static or frequency domain loading conditions. This paper briefly introduces flexible multibody system dynamics and structural optimization techniques. Afterwards, the two main methods, named the weakly and the fully coupled methods, that couple both disciplines are presented in details and the influence of the multibody system formalism is analyzed. The advantages and drawbacks of both methods are discussed and future possible research areas are mentioned