topology optimization of aeronautical structures with
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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]
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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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Table 3 Summary of the most important parameters
and results for the structural topology optimi-
zation of an arc section located in the rear part
of a plane
Arc m(constraints) " p Final Weight
Initial Weight %
Local approach 4650 0.02 4.00 15.80Block aggregated
approach186 0.02 4.00 14.34
Topology optimization of aeronautical structures with stress constraints 599
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