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    Topology optimization of aeronautical structures withstress constraints: general methodology andapplicationsJ Pars*, S Martnez, F Navarrina, I Colominas, and M Casteleiro

    Department of Applied Mathematics, Universidade da Coruna, A Coruna, Spain

    The manuscript was received on 22 March 2010 and was accepted after revision for publication on 6 May 2011.

    DOI: 10.1177/0954410011411632

    Abstract: Structural optimization is a well known and frequently used discipline in aerospaceapplications since most of the optimization problems were stated in order to solve aeronauticstructures. Since first works about structural topology optimization were published, differentformulations have been proposed to obtain the most adequate design. Topology optimizationof structures is the most recent branch of structural optimization. The first works about this topic

    were proposed by Bendsoe and Kikuchi in 1988 (Bendsoe, M. P. and Kikuchi, N. Generatingoptimal topologies in structural design using a homogenization method. Comput. Methods Appl.Mech. Engng., 1988,71, 197224). In this field of structural optimum design, the aim is to obtainthe optimal material distribution of a given amount of material in a predefined domain. The mostusual formulation tries to maximize the stiffness of the structure by using a given amount ofmaterial. In this paper, we present a minimum weight formulation with stress constraints thatallows to avoid most of the drawbacks associated to maximum stiffness approaches. The pro-posed formulation is applied to the optimization of aeronautical structures. Some examples have

    been studied in order to validate the formulation proposed.

    Keywords: topology optimization, aeronautic structures, minimum weight, stress constraints,finite-element modelling

    1 INTRODUCTION

    The optimization of the topology of structures is a

    relatively recent discipline in the field of structural

    optimization. Since the first model was introduced

    two decades ago [1] a lot of effort has been dedi-

    cated to deal with this problem. However, most of

    the effort in this area has been focused on the cre-

    ation of maximum stiffness formulations due to

    computational reasons, among other considerations

    [15]. Recently, approaches that use stress (and/or

    displacement) constraints have been proposed

    since they possess the appealing characteristics of

    avoiding checkerboard solutions and guaranteeing

    the feasibility of the solution [612]. However,

    these formulations require significant computing

    resources since the underlying optimization prob-

    lem is much more complicated. This is a crucial

    aspect since practical topology optimization prob-

    lems usually involve a very large number of design

    variables and a very large number of non-linear

    stress constraints. However, the use of constraints

    (stress, displacements, buckling, etc.) in topology

    optimization problems produces more realistic

    and reliable formulations, and the solutions

    obtained satisfy the requirements imposed in engi-

    neering projects (minimum cost, bearing capacity,

    safety, etc.).

    The maingoal of thispaper is to present a model for

    the topology optimization problem in aeronautical

    applications that is based on the minimization

    of the weight with stress constraints. The mainadvantages and drawbacks of this formulation are

    explained and some modifications are proposed in

    *Corresponding author: Group of Numerical Methods in

    Engineering, GMNI, Department of Applied Mathematics,

    School of Civil Engineering, Universidade da Coruna, Campus

    de Elvina, 15071, A Coruna, Spain.

    email: [email protected]

    589

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    order to reduce the most critical aspects from numer-

    ical and computational points of view (computing

    cost, feasibility, robustness). Three different appro-

    aches for structural topology optimization that incor-

    porate stress constraints are proposed in orderto analyse the obtained improvements. Special

    effort is devoted to the analysis of techniques that

    reduce the computational requirements. In addition,

    a modified minimum-weight objective function is

    proposed in order to obtain an essentially binary opti-

    mum solution by using continuum design variables.

    Finally, some aeronautical structures are optimized

    in order to verify the feasibility of the proposed

    models.

    2 TOPOLOGY OPTIMIZATION PROBLEM

    Minimum-weight formulations for the topology

    optimization of continuum structures with stress

    constraints try to obtain the best distribution of

    material in a predefined domain such that the

    weight (or the cost) is minimized and stress (and/

    or displacement) constraints are satisfied. Thus, the

    main goal of this problem is to decide the optimal

    distribution of material. According to this idea, the

    material distribution is binary since each point of

    the domain has two possible states: solid material

    or void. This binary approach corresponds to theoriginal formulation of the structural topology opti-

    mization problem. In practice, discrete optimization

    with a large number of design variables and con-

    straints is a challenging problem that has yet to be

    correctly solved. Consequently, most of the formu-

    lations proposed in the literature state the problem

    by means of continuum approaches to the material

    distribution. These continuum approaches require

    the use of a continuum design variable that defines

    the material state: the so-called relative density ().

    Thus, the relative density takes the values [0,1]. The

    value 0 means no material and 1 meanssolid material. In addition, microstructure models

    are required to perform the structural analysis for

    intermediate values of the relative density (e.g. solid

    isotropic material with penalization (SIMP), hole-in-

    cell, rank-layered, etc. [14]). The most usual

    microstructure model in topology optimization of

    structures is SIMP. A minimum-weight approach

    with continuum design variables is presented in

    this paper. These variables correspond to the rela-

    tive density of each one of the elements used in a

    finite-element modelling (FEM) discretization. The

    relative density is assumed uniform for each ele-ment of the mesh. The microstructure model used

    in this paper is based on a SIMP approach.

    According to these statements, the minimum-

    weight topology optimization problem with stress

    constraints can be written as

    find

    feg e1,. . .

    , Nethat minimizes F verifying gj 40 j1, . . . , m

    05min4e41 e1, . . . , Ne

    1

    where the design variableeis the relative density of

    elemente(assumed uniform within the element) and

    Ne is the total number of elements in the mesh. The

    lower limit of the relative density,min, usually takes

    values slightly higher than zero to avoid the stiffness

    matrix becoming singular.

    2.1 Objective function

    According to the previous explanations, the model of

    the microstructure used in the proposed formulation

    is based on a SIMP model without any penalization of

    the intermediate densities. In this formulation the

    penalization of the intermediate densities is included

    in the objective function as

    F XNe

    e1

    e1=p

    Ze matd 2whereeis the element numbere,matis the density

    of the material, andp51 is the penalization param-

    eter of the intermediate densities. This penalization

    parameter is used to favour a mainly solidvoid dis-

    tribution of material [13]. This objective function

    can be modified in order to improve the obtai-

    ned solutions. A modified objective function that

    included a penalization on the perimeter of the struc-

    ture was proposed in reference [14]. This perimeter

    penalization avoided some unexpected phenomena

    and produced optimal solutions with a smallernumber of structural elements (trusses).

    Objective function (2) can be complemented with a

    modified objective function at the end of the optimi-

    zation process that forces the material distribution

    to be binary although the design variables are con-

    tinuous. The modified objective function can be

    written as

    F XNee1

    Ze

    bematd 3

    where

    be 1=12

    e sine expe 4

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    The parameter must take values in the interval

    [0.260, 7.404] in order to avoid positive derivatives of

    the objective function when e !1. The optimiza-

    tion process is developed in two stages. In the first

    stage, the optimization process is developed byusing the objective function proposed in equation

    (2) until convergence. The second optimization pro-

    cess starts with the solution obtained in the first

    stage. The parameter is usually modified during

    the optimization process. The initial steps are devel-

    oped using a small value of the parameter (for

    instance, 1:0) which is increased until the max-

    imum value is reached. Finally, the process con-

    tinues until convergence by using the maximum

    value of the parameter ( 7:404). In practice, a

    large number of iterations are required in this

    second stage, but this is not overly restrictive froma CPU time point of view. In very specific cases the

    value of can temporarily take values over 7.404 but

    at the end of the optimization stage the limit values

    must be satisfied in order to obtain an essentially

    binary solution.

    2.2 Stress constraints

    The formulation proposed for the structural topology

    optimization problem tries to minimize the previ-

    ously introduced objective function while taking

    into account stress constraints. In this paper, threedifferent formulations are presented and analysed

    in order to deal with stress constraints. The first pro-

    posed model is based on a local approach to the state

    stress constraints. In this formulation one stress con-

    straint at the central point of each element is imposed

    [68, 13, 14]. Thus, each local stress constraint can be

    introduced as

    ge he

    maxe

    e

    q40 5

    and

    e

    1

    " "

    e6

    where geis the stress constraint of the element eand

    is the reference stress (usually the von Mises crite-

    rion) obtained through the calculated stress tensor

    heat the central point of the element. This local con-

    straint is relaxed using the function eproposed in

    equation (6) in order to avoid singularity phenom-

    enon when the relative density tends to zero [69,

    13, 14]. The relaxation parameter " usually takes a

    value in the interval [0.001,0.1]. In addition, the expo-

    nent qallows one to deal with the real stress (when

    q 0) or the effective stress (whenq 1). The use of

    effective stresses creates important advantages sinceit avoids discontinuities when the relative density

    tends to zero (see [13,14,15] for more details).

    The local approach to stress constraints usually

    requires a large number of constraints to be imposed

    due to the number of elements (and design variables)

    involved in the structural analysis (by means of FEM).

    Consequently, this approach requires significantcomputing resources when thousands of design vari-

    ables are used. Due to this fact, alternative formula-

    tions have been derived in order to reduce the

    computational cost. In this paper two additional for-

    mulations of the stress constraints are introduced: a

    global approach that aggregates the effect of all the

    local constraints [13] and a block aggregation tech-

    nique that aggregates the local constraints of a pre-

    defined set of elements of the mesh and then uses

    them to state a global constraint [14]. Thus, the

    number of constraints is equal to the number of

    defined groups of elements. Each group of elementsis usually called a block and, consequently, the pro-

    posed formulation is called the block aggregated

    approach to stress constraints.

    The global approach aggregates all the local

    constraints by using a global function. The global

    function used in this paper is the Kreisselmeier

    Steinhauser function (also used, for example, in refer-

    ence [16]) that can be written as

    GKS 1

    ln

    XNe

    e1

    ee1

    !

    1

    lnNe

    " #40 7

    with

    e he

    maxe8

    being the normalized reference stress. The coefficient

    proposed in equation (8) is the aggregation param-

    eter and usually takes values 2 20, 40(see [13,14,

    17] for more details). Values of520 allow excessive

    violation of the local constraints. Values of 440

    excessively increase the non-linearity of the global

    functions.

    This formulation reduces the required computingcost since the number of stress constraints decreases.

    The local approach imposes as many constraints as

    design variables multiplied by the number of load

    cases. In contrast, the global approach imposes only

    one stress constraint per load case.

    However, when the number of design variables

    (and, consequently, the number of elements)

    increases, the global approach aggregates thousands

    of local constraints. Thus, the aggregation of a large

    number of constraints means a loss of information

    about local contributions. Consequently, the sensitiv-

    ity analysis becomes useless in practice for the opti-mization algorithms when the global approach is

    used.

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    Due to this fact, a different formulation of the stress

    constraints is proposed that combines the advantages

    of the global and local approaches: the previously

    introduced block aggregated approach of the stress

    constraints. This formulation defines groups of ele-ments called blocks. Each block contains approxi-

    mately the same number of elements.

    The main goal of this approach is to impose a global

    constraint that aggregates the contributions of the

    elements contained in a block. Thus, the number of

    constraints imposed is equal to the number of blocks

    defined. In addition, the number of local constraints

    aggregated in a global function is much smaller than

    the number of design variables. The global function

    obtained by aggregating the elements of each block is

    defined according to equation (7) as

    GbKS 1

    ln

    Xe2Bb

    e e1

    !

    1

    ln Nbe " #

    40 9

    where eis the normalized reference stress presented

    in equation (8),Nbe is the number of elements aggre-

    gated in blockb, and Bbis the set of elements stated in

    blockb.

    This formulation is more general than the local and

    global approaches and includes them as special cases

    [13, 14]. When the number of blocks is equal to the

    number of elements, the block aggregated approach

    is equivalent to the local constraints approach. If thenumber of blocks is equal to one, this formulation is

    equivalent to the global approach.

    The number of blocks used and the way of defining

    the geometry of the blocks are the most important

    features of this formulation. However, it has been

    observed by the authors that the geometry of the

    blocks does not significantly influence the final solu-

    tion. The number of blocks and the aggregation

    parameter are much more critical [13,14].

    3 OPTIMIZATION ALGORITHM

    Based on the approaches introduced in the previous

    section, the topology optimization of structures using

    stress constraints leads to mathematical program-

    ming problems of the type stated in equation (1)

    with highly non-linear constraints of the type stated

    in equations (5), (7), or (9) and a non-linear objective

    function like the one proposed in equation (2) or in

    equation (3). In practical applications, FEM meshes

    may produce thousands of design variables and

    thousands of stress constraints in two-dimensional

    (2D) problems (when the local approach is used).

    In three-dimensional problems the number of vari-ables dramatically increases. Thus, the optimization

    algorithms used to solve this problem must be

    appropriate and specific. Otherwise, the computa-

    tional costs will become unaffordable in practice. In

    addition, non-specific algorithms may not reach the

    optimal solution.

    In this paper we propose an improved SLPalgorithm with quadratic line search to solve the

    optimization problem [13,14,15,17]. This algorithm

    analyses a linearized approach to problem (1) in all

    iterations of the optimization process. In addition,

    side constraints of the design variables need to be

    imposed. The search direction is obtained by means

    Fig. 1 Scheme of the geometry (in millimetres), the

    prescribed displacements, the loads applied,and the FEM mesh with 4014 quadrilateraleight-node elements used for the structuraloptimum design of an undercarriage

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    of the Simplex algorithm [18]. Then, the advance

    factor that multiplies the search direction is obtained

    by using a directional second-order Taylor expansion

    [13,15].

    This algorithm has been demonstrated to workproperly for this optimization problem. In fact the

    algorithm has an adequate performance in both

    opposite situations: when thousands of local stress

    constraints are considered (local approach) and

    when a reduced number of global stress constraints

    is considered (block aggregated approach).

    4 SENSITIVITY ANALYSIS

    The required sensitivity analysis is obtained analyti-

    cally since the resulting algorithms are mathemati-

    cally exact and efficient and they produce adequatecalculations of the derivatives.

    First and second-order derivatives of the objective

    function are obtained by applying a direct differenti-

    ation algorithm. This algorithm is directly obtained

    from equation (2) or equation (3), respectively, for

    each formulation of the objective function by using

    the differentiation rules.

    Fig. 3 Normalized stress state defined according toequation (8) of the optimum structure of anundercarriage obtained using the localapproach of stress constraints

    Fig. 2 Optimum structure for an undercarriageobtained using the local approach of stressconstraints

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    First-order derivatives of the stress constraints are

    obtained by using an adjoint variable approach [13,

    14, 15, 19]. This formulation allows to obtain first-

    order derivatives of a set of active (almost violated)

    stress constraints and it requires less computationaleffort than a direct differentiation approach [13, 14,

    15,19]. In practice, only first-order derivatives of the

    active stress constraints are computed in order to

    reduce the required computing time. First and

    second-order directional derivatives of all the stress

    constraints are obtained by using a direct differenti-

    ation technique since it requires less computational

    effort than the adjoint variable approach. In addition,

    this technique allows one to compute the first

    and second-order directional derivatives of all stress

    constraints even though the whole set of first-

    Fig. 4 Optimum structure of an undercarriageobtained using the local approach of stressconstraints and the modified objectivefunction

    Fig. 5 Normalized stress state of the optimum struc-ture of an undercarriage obtained using thelocal approach of stress constraints and themodified objective function

    Table 1 Summary of the most important parameters

    and results for the structural topology optimi-

    zation of an undercarriage

    Undercarriage m(constraints) " p, Final weightInitial weight %

    Local approach 4014 0.01 4.00 8.30Modified

    objective4014 0.01 7.00 18.72

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    Fig. 6 Scheme of the geometry (in millimetres), the prescribed displacements, the applied loads,and the FEM mesh with 5200 eight-node quadrilateral elements used for the optimumdesign of a structural section of a VTP/HTP

    Fig. 9 Optimal solution obtained using the local approach of the stress constraints and the mod-ified objective function proposed in equation (3) for a structural section of a VTP/HTP

    Fig. 10 Normalized stress state, obtained based on equation (8), of the optimal solution presentedin Fig. 9

    Fig. 8 Normalized stress state, obtained based on equation (8), of the optimal solution presented inFig. 7

    Fig. 7 Optimal solution obtained using the local approach of the stress constraints for a structuralsection of a VTP/HTP

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    order derivatives has not been previously calculated.

    The complete sensitivity analysis procedure was

    developed by the current authors in a previous pub-

    lication [19].

    5 APPLICATION EXAMPLES

    The application examples presented correspond to

    2D structures in plane stress. Three different exam-

    ples have been analysed. The first problem corre-

    sponds to the structural optimum design of the

    undercarriage of a small plane. The second example

    corresponds to the optimization of a section of a ver-

    tical/horizontal tail plane (VTP/HTP).The third

    example corresponds to the structural optimum

    design of an arc section in the rear part of a plane

    that bears the VTP. The computations were per-formed on computing nodes with two Quad-Core

    processors (2.83 GHz, 1333 MHz FSB) and 32 Gb of

    RAM.

    5.1 Structural optimum design of an

    undercarriage

    The first example corresponds to the optimum design

    of the undercarriage of a small plane. Null displace-

    ments of the structure are imposed in the striped part

    of the upper edge. A vertical distributed force of 5550

    kN/m is applied on the lower vertical edge.Figure 1 shows the dimensions of the domain and

    the position of the external load. The domain of the

    structure is discretized by using 4014 eight-node

    quadrilateral elements. The material being used is

    steel alloy AISI-4340 with density mat7850 kg/

    m3, Youngs modulus E 200 GPa, Poissons ratio

    0:3, and elastic limit max1790 MPa. The thick-

    ness of the structure is 0:1 m. Figure 2 shows the

    optimal solution for the undercarriage problem

    obtained using the local approach of stress con-

    straints. Figure 3 shows the normalized stress state

    according to equation (8). Figure 4 shows the optimalsolution for the undercarriage problem obtained by

    using the local approach of stress constraints. This

    solution includes a second optimization stage that

    considers the modified objective function proposed

    in equation (3). Figure 5 shows the normalized stress

    state for this problem according to equation (8).

    The most relevant parameters and results obtained

    for this problem can be observed in Table 1. From this

    table it can be observed that the weight of the opti-

    mum solution obtained with the modified objective

    function is higher than the one obtained with the min-

    imum weight with penalization approach. This factcan be easily explained since the modified objective

    function forces binary solutions and this is a very

    important design limitation. However, the solution

    obtained by using the modified objective function

    has multiple advantages since the number of elements

    with intermediate relative density has been decreased.

    5.2 Optimum design of a structural section in

    the VTP/HTP of a plane

    The second example corresponds to the topology

    optimization of a structural section in the VTP/HTP

    of a plane. Null displacements are imposed on the

    edge of the left circumference. A distributed force of

    12 kN/m is applied orthogonally on the lower edge of

    the section (along 76.6 cm). The dimensions of the

    domain and the position of the external loads can

    be observed in Fig. 6. The domain of the structure is

    discretized using 5200 eight-node quadrilateral ele-ments. Only the lower half of the structure needs to

    be analysed due to the symmetry of the geometry and

    the applied loads. The material being used is an

    aluminium alloy with density mat2770 kg/m3,

    Youngs modulus E 73 GPa, Poissons ratio

    0:3, and elastic limit max430 MPa. The thick-

    ness of the structure is 0:01 m.

    Figure 7 shows the optimum solution for a struc-

    tural section in the VTP/HTP obtained using the local

    approach of stress constraints. The normalized stress

    state (represented using equation (8)) can be

    observed in Fig. 8. Figure 9 shows the optimum solu-tion of a structural section in the VTP/HTP obtained

    using the local approach of stress constraints. This

    solution includes a second optimization stage that

    considers the modified objective function pro-

    posed in equation (3). The normalized stress state

    (obtained according to equation (8)) can be observed

    in Fig. 10.

    Table 2 shows the most important parameters for

    this formulation and the most representative results

    for the optimization of the VTP/HTP. It can be

    observed that the optimal solution obtained with

    the modified objective function presents an almostbinary solution. However, the weight of the solution

    obtained with the modified objective function is

    higher than the one obtained with the minimum-

    weight approach with penalization since the require-

    ment of a binary solution is a strong design limitation.

    Table 2 Summary of the most important parameters

    and results for the topology optimization of a

    structural section in a VTP/HTP

    VTP / HTP m(constraints) " p, Final weightInitial weight

    %

    Local approach 5200 0.015 4.00 9.37Modified

    objective5200 0.010 7.00 19.98

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    Fig. 14 Optimal solution obtained using the block aggregated approach of the stress constraintsand the modified objective function proposed in equation (3) for the topology optimizationof an arc section located in the rear part of a plane

    Fig. 15 Normalized stress state, obtained according to equation (8), of the optimal solution pre-sented in Fig. 14

    Fig. 13 Normalized stress state, computed according to equation (8), of the optimal solutionobtained for an arc section located in the rear part of a plane

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    force binary material distributions as it has been pre-

    viously explained. On the other hand, the normalized

    stress states obtained from the two formulations are

    different. The normalized stress state when the local

    approach is used (Fig. 13) is strictly satisfied from a

    local point of view. On the other hand, the normalizedstress state for the block aggregated approach solu-

    tion (Fig. 15) does not strictly satisfy the stress con-

    straints from a local point of view. Thus, the local

    approach is more reliable than the block aggregated

    approach. The main advantage of the block aggre-

    gated approach is the obtained reduction in comput-

    ing time. This is a result of the small number of

    constraints involved, which are reduced from 4650

    (local approach) to 186 (block aggregated approach).

    The CPU time can be usually decreased one order of

    magnitude with this kind of formulation in practical

    applications.Table 3 shows the most important parameters and

    the most representative results for the optimum

    design of a structural arc located in the rear part of

    a plane.

    The application examples clearly show that the pro-

    posed formulations are able to deal with structural

    problems in aeronautic applications. Structural prob-

    lems with thousands of design variables and thou-

    sands of non-linear stress constraints are solved and

    appropriate solutions are obtained.

    6 CONCLUSIONS

    A minimum-weight approach for the topology opti-

    mization of structures with stress constraints has

    been proposed in this paper. This model is based on

    a continuum approach to the design variables by

    using a SIMP approach without penalization of the

    intermediate relative densities.

    The penalization of the intermediate relative den-

    sities is included in a modified minimum-weight

    objective function that allows 0-1 binary distributions

    of material to be favoured. The presented formula-

    tions also include stress constraints in order toverify the structural feasibility since material failure

    is checked and avoided. Three different formulations

    of stress constraints are presented in order to study

    the advantages that they offer (computing cost,

    robustness, reliability, etc.): the local approach, the

    global approach, and the block aggregated approach.

    The proposed formulations do not require the use ofany image filtering technique in order to avoid check-

    erboard solutions. The optimal solutions are directly

    obtained from the analysis and do not include any

    smoothing or filtering treatment.

    Finally, some application examples related to aero-

    nautic and astronautic industries are solved in order

    to verify the proposed formulation and the applied

    optimization methodology. These examples contain

    a large number of design variables and constraints,

    which indicates the robustness of the proposed for-

    mulation to solve structural topology optimization

    problems in aeronautical applications.

    ACKNOWLEDGEMENTS

    This work was partially supported by the Ministerio

    de Educacion y Ciencia of the Spanish Government

    (grants DPI2009-14546-C02-01 and DPI2010-16496),

    by FEDER funds from the Autonomous Government

    of the Xunta de Galicia (grants PGDIT09MDS00718PR

    and PGDIT09REM005118PR), by the Universidade da

    Coruna, and by the Fundacion de la Ingeniera Civil

    de Galicia.

    Authors 2011

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