An incremental high-cycle fatigue damage model is combined with topology optimization to design structures subject to non-proportional loads. The optimization aims to minimize the mass under compliance and fatigue constraints. The fatigue model is based on the concept of an evolving endurance surface and a system of ordinary differential equations that model the local fatigue damage evolution. A recent model extension that uses a quadratic polynomial endurance function to enhance the accuracy and extrapolation capabilities, especially for non-proportional loads, is used. To enable computationally efficient design updates, an adjoint sensitivity analysis that is consistent with the state solution, requiring only a few linear solves involving the stiffness matrix is derived. Furthermore, a new compliance constraint is developed for uncorrelated, stochastic force components to take worst-case force combinations into account. Numerical examples in both 2D and 3D demonstrate that the proposed framework is able to design structures subject to non-proportional loads.

We present a new topology optimization problem formulation for conjugate heat transfer problems based on minimizing temperature subject to mass flow constraints on the flow of a cooling medium and show well-posedness of the continuum problem. A version of the problem augmented with a lower bound on the stiffness of the designs is considered in numerical examples loosely based on a real design case for a gas turbine part. The numerical examples indicate that the proposed problem formulation can be used to obtain designs which are useful from an engineering perspective.

A topology optimization formulation including a model of the layer-by-layer additive manufacturing (AM) process is considered. Defined as a multi-objective minimization problem, the formulation accounts for the performance and cost of both the final and partially manufactured designs and allows for considering AM-related issues such as overhang and residual stresses in the optimization. The formulation is exemplified by stiffness optimization in which the overhang is limited by adding mechanical or thermal compliance as a measure of the cost of partially manufactured designs. Convergence of the model as the approximate layer-by-layer model is refined is shown theoretically, and an extensive numerical study indicates that this convergence can be fast, thus making it a computationally viable approach useful for including AM-related issues into topology optimization. The examples also show that drips and sharp corners associated with some geometry-based formulations for overhang limitation can be avoided. The codes used in this article are written in Python using only open sources libraries and are available for reference.

When exposed to cyclic quasi-static loading, elastic bodies in contact may develop a favourable condition where slip ceases after a few cycles, an occurrence commonly known as frictional shakedown. If the amplitude of the cyclic load is greater than a so-called shakedown limit, shakedown cannot occur. In this review paper, the validity of shakedown theorems in the context of conforming contacts with à la Coulomb friction is first discussed. Then, an optimisation method for determining the shakedown limit of elastic discrete three-dimensional systems is reviewed. Finally, an incremental Gauss–Seidel algorithm, extended to three-dimensional systems, is here illustrated in details for the first time. The algorithm allows us to describe the transient response of normal-tangential coupled systems under a given cyclic loading scenario, and to determine their possible shakedown depending on the initial conditions. An example concerning a discrete conforming contact problem, where either coupling or uncoupling conditions can be imposed, is illustrated.

An efficiency-enhanced procedure to treat continuous-time, high-cycle fatigue (HCF) constraints in topology optimization is presented. The HCF model predicts the evolution of fatigue damage at each point in the design domain using a system of ordinary differential equations. We employ gradient-based optimization and the fatigue sensitivities are determined using adjoint sensitivity analysis. As the predicted damage has history dependence, adjoint variables are solved via a stepwise backward procedure. Therefore, the computational cost increases in proportion to the number of time steps. To reduce this cost, we propose an extrapolation technique which is valid for all forms of periodic, proportional loads and most non-proportional loads and allows treatment of essentially an unlimited number of load cycles. Using this technique, several problems in both 2D and 3D are solved numerically where the objective is to minimize structural mass subjected to a fatigue constraint.

We propose a topology optimization method for design of transversely isotropic elastic continua subject to high-cycle fatigue. The method is applicable to design of additive manufactured components, where transverse isotropy is often manifested in the form of a lower Young’s modulus but a higher fatigue strength in the build direction. The fatigue constraint is based on a continuous-time model in the form of ordinary differential equations governing the time evolution of fatigue damage at each point in the design domain. Such evolution occurs when the stress state lies outside a so-called endurance surface that moves in stress space depending on the current stress and a back-stress tensor. Pointwise bounds on the fatigue damage are approximated using a smooth aggregation function, and the fatigue sensitivities are determined by the adjoint method. Several problems where the objective is to minimize mass are solved numerically. The problems involve non-periodic proportional and non-proportional load histories. Two alloy steels, AISI-SAE 4340 and 34CrMo6, are treated and the respective as well as the combined impact of transversely isotropic elastic and fatigue properties on the design are compared.

SummaryWe consider structural optimization (SO) under uncertainty formulated as a mathematical game between two players –– a “designer” and “nature”. The first player wants to design a structure that performs optimally, whereas the second player tries to find the worst possible conditions to impose on the structure. Several solution concepts exist for such games, including Stackelberg and Nash equilibria and Pareto optima. Pareto optimality is shown not to be a useful solution concept. Stackelberg and Nash games are, however, both of potential interest, but these concepts are hardly ever discussed in the literature on SO under uncertainty. Based on concrete examples of topology optimization of trusses and finite element‐discretized continua under worst‐case load uncertainty, we therefore analyze and compare the two solution concepts. In all examples, Stackelberg equilibria exist and can be found numerically, but for some cases we demonstrate nonexistence of Nash equilibria. This motivates a view of the Stackelberg solution concept as the correct one. However, we also demonstrate that existing Nash equilibria can be found using a simple so‐called decomposition algorithm, which could be of interest for other instances of SO under uncertainty, where it is difficult to find a numerically efficient Stackelberg formulation.

We propose a topology optimization method that includes high-cycle fatigue as a constraint. The fatigue model is based on a continuous-time approach where the evolution of damage in each point of the design domain is governed by a system of ordinary differential equations, which employs the concept of a moving endurance surface being a function of the stress and back stress. Development of fatigue damage only occurs when the stress state lies outside the endurance surface. The fatigue damage is integrated for a general loading history that may include non-proportional loading. Thus, the model avoids the use of a cycle-counting algorithm. For the global high-cycle fatigue constraint, an aggregation function is implemented, which approximates the maximum damage. We employ gradient-based optimization, and the fatigue sensitivities are determined using adjoint sensitivity analysis. With the continuous-time fatigue model, the damage is load history dependent and thus the adjoint variables are obtained by solving a terminal value problem. The capabilities of the presented approach are tested on several numerical examples with both proportional and non-proportional loads. The optimization problems are to minimize mass subject to a high-cycle fatigue constraint and to maximize the structural stiffness subject to a high-cycle fatigue constraint and a limited mass.

Metal AM (additive manufacturing) components are generally inhomogeneous and have different microstructure in the bulk compared with (contour) regions near the surface. This, as well as rough as-built surfaces, affects mechanical properties. In this paper, we develop a topology optimization method that considers such inhomogeneities. The method is a direct extension of standard density-based methods using linear filtering for regularization, and a second filtering of the design variables is used to identify a surface layer, the thickness of which is given by the filter radius. Domain extension is used in order to properly identify such layers at the boundary of the design domain. The method is generally applicable but is demonstrated for stiffness optimization. Both two- and three-dimensional problems are treated. A general property of the method is that the topological complexity is reduced, i.e. the optimized designs get fewer and thicker structural members as the width of the surface layer is increased.

The properties of the continuous-time, high-cycle fatigue model of Ottosen et al. (2008) is investigated for challenging stress states. We derive an analytical solution to the damage per cycle for cyclic, proportional stress. Numerical investigations for 7050-T7451 aluminum alloy and AISI 4340 steel alloy show exponential convergence to a constant damage per cycle for cyclic proportional stress, and Wynn’s epsilon algorithm for sequence acceleration improves the convergence rate. Fatigue damage is well predicted for an applied proportional stress, but damage is severely underpredicted for rotary stress states or combinations of tension/compression and torsion.

We consider a model for density-based topology optimization (TO) of stationary heat transfer problems with design-dependent internal convection in 3D structures with periodic design obtained by extruding a 2D design in 3D. The internal convection takes place at the interface between a solid material and a cooling fluid in internal channels through the design domain. The objective of the TO is to minimize the maximum temperature, which is approximated by means of an Lp norm. The finite element method is used to discretize the state problem and the resulting optimization problem is solved using gradient-based methods. The internal convection is modeled to be dependent on the design density gradient in the continuous problem. In discrete form, it is approximated as proportional to the difference in design densities of adjacent elements in the finite element mesh. The theory is illustrated by numerical examples based on a simplified guide vane geometry.

Several filter approaches that introduce additive manufacturing-related overhang constraints in topology optimization exist. However, a drawback of these is that exact satisfaction of overhang constraints produces sharp inward corners resulting in stress singularities. The present paper therefore modifies such filter approaches by a penalty formulation, where the choice of penalty factor regulates how closely the overhang constraint is satisfied. By appropriately choosing certain weight factors in the penalty function, the cost of support structures is also reflected in the formulation in a simple and computationally inexpensive way. The method is demonstrated by parameter studies using the classical MBB beam, using both structured and unstructured meshes.

We develop a topology optimization method including high-cycle fatigue as a constraint. The fatigue model is based on a continuous-time approach, which uses the concept of a moving endurance surface as a function of the stress history and back stress evolution. The development of damage only occurs when the stress state lies outside the endurance surface. Furthermore, an aggregation function, which approximates the maximum fatigue damage, is implemented. As the optimization workflow is sensitivity-based, the fatigue sensitivities are determined using an adjoint sensitivity analysis. The capabilities of the presented approach are tested on numerical models where the problem is to maximize the stiffness subject to high-cycle fatigue constraints.

Background:In scoliosis, kypholordos and wedge properties of the vertebrae should be involved in determining how stress is distributed in the vertebral column. The impact is logically expected to be maximal at the apex.Aim:To introduce an algorithm for constructing artificial geometric models of the vertebral column from DICOM stacks, with the ultimate aim to obtain a formalized way to create simplistic models, which enhance and focus on wedge properties and relative tilting.Material/Methods:Our procedure requires parameter extraction from DICOM image-stacks (with PACS,IDS-7), mechanical FEM-modelling (with Matlab and Comsol). As a test implementation, models were constructed for five patients with thoracal idiopathic scoliosis with varying apex rotation. For a selection of load states, we calculated a response variable which is based upon distortion energy.Results:For the test implementation, pairwise t-tests show that our response variable is non-trivial and that it is chiefly sensitive to the transversal stresses (transversal stresses where of main interest to us, as opposed to the case of additional shear stresses, due to the lack of explicit surrounding tissue and ligaments in our model). Also, a pairwise t-test did not show a difference (n = 25, p-value≈0.084) between the cases of isotropic and orthotropic material modeling.Conclusion:A step-by-step description is given for a procedure of constructing artificial geometric models from chest CT DICOM-stacks, such that the models are appropriate for semi-global stress-analysis, where the focus is on the wedge properties and relative tilting. The method is inappropriate for analyses where the local roughness and irregularities of surfaces are wanted features. A test application hints that one particular load state possibly has a high correlation to a certain response variable (based upon distortion energy distribution on a surface of the apex), however, the number of patients is too small to draw any statistical conclusions.

Fatigue cracked primary aircraft structural parts that cannot be replaced need to be repaired by other means. A structurally efficient repair method is to use adhesively bonded patches as reinforcements. This paper considers optimal design of such patches by minimizing the crack extension energy release rate. A new topology optimization method using this objective is developed as an extension of the standard SIMP compliance optimization method. The method is applied to a cracked test specimen that resembles what could be found in a real fuselage and the results show that an optimized adhesively bonded repair patch effectively reduces the crack energy release rate.

The growth and remodeling of arteries, as controlled by the local stress state and the sensory input from the endothelial cells of the artery wall, is given a novel theoretical framework incorporating the active behavior of vascular smooth muscle. We show that local sensory input maps uniquely to the ratio between a target arterial wall cross-section area corresponding to homeostatic conditions and the current arterial wall area. A growth law is formulated by taking the production rates of individual constituents of the arterial wall to be functions of this target-to-current wall area ratio. We find that a minimum active stress response of vascular smooth muscle is necessary to achieve stable adaptation of the artery wall to dynamic flow conditions. With a sufficient active stress alteration in response to stretch, stable growth toward a homeostatic state can be observed for finite step changes or ramp changes in the transmural pressure or the flow rate.

A design problem of finding an optimally stiff membrane structure by selecting one–dimensional fiber reinforcements is formulated and solved. The membrane model is derived in a novel manner from a particular three-dimensional linear elastic orthotropic model by appropriate assumptions. The design problem is given in the form of two minimization statements. After finite element discretization, the separate treatment of each of the two statements follows from classical results and methods of structural optimization: the stiffest orientation of reinforcing fibers coincides with principal stresses and the separate selection of density of fibers is a convex problem that can be solved by optimality criteria iterations. Numerical solutions are shown for two particular configurations. The first for a statically determined structure and the second for a statically undetermined one. The latter shows related but non-unique solutions.

Complete frictional contacts, when subjected to cyclic loading, may sometimes develop a favourable situation where slip ceases after a few cycles, an occurrence commonly known as frictional shakedown. Its resemblance to shakedown in plasticity has prompted scholars to apply direct methods, derived from the classical theorems of limit analysis, in order to assess a safe limit to the external loads applied on the system. In circumstances where zones of plastic deformation develop in the material (e.g., because of the large stress concentrations near the sharp edges of a complete contact), it is reasonable to expect an effect of mutual interaction of frictional slip and plastic strains on the load limit below which the global behaviour is non dissipative, i.e., both slip and plastic strains go to zero after some dissipative load cycles. In this paper, shakedown of general two-dimensional discrete systems, involving both friction and plasticity, is discussed and the shakedown limit load is calculated using a non-linear programming algorithm based on the static theorem of limit analysis. An illustrative example related to an elastic-plastic solid containing a frictional crack is provided.