Kuang-Hua Chang

A study of design velocity field computation for shape optimal design

Abstract Design velocity field computation is an important step in computing shape design sensitivity coefficients and updating a finite element mesh in the shape design optimization process. Applying an inappropriate design velocity field for shape design sensitivity analysis and optimization will yield inaccurate sensitivity results or a distorted finite element mesh, and thus fail in achieving an optimal solution. In this paper, theoretical regularity and practical requirements of the design velocity field are discussed. The crucial step of using the design velocity field to update the finite element mesh in the design optimization process is emphasized. Available design velocity field computation methods in the literature are summarized and their applicability for shape design sensitivity analysis and optimization is discussed. Five examples are employed to discuss applicability of these methods. It was found that a combination of isoparametric mapping and boundary displacement methods is ideal for the design velocity field computation.

A CAD-based design parameterization for shape optimization of elastic solids

Abstract In this paper a CAD-based design sensitivity analysis (DSA) and optimization method using Pro/ENGINEER for shape design of structural components is presented. The CAD-based design model is critically important for multidisciplinary shape design optimization. Only when each discipline can compute the design sensitivity coefficients of the CAD-based design model, can a true multidisciplinary what-if study, trade-off analysis, and design optimization be carried out. The proposed method will allow the design engineer to compute design sensitivity coefficients of structural performance measures such. as stress and displacement, evaluated using existing finite element analysis (FEA) tools, both h- and p-versions, with respect to design variables defined in the parameterized CAD model. The proposed method consists of (i) a CAD-based design parameterization technique that ties the structural DSA and optimization to a CAD tool; (ii) a design velocity field computation that defines material point movement due to design change in CAD geometry, satisfies linearity and regularity requirements, and supports both hand p-version FEA meshed using existing mesh generators; and (iii) a design optimization method that supports structural geometric and finite element model updates in Pro/ENGINEER during the optimization process.

A geometry-based parameterization method for shape design of elastic solids

ABSTRACT One of the major difficulties in structural shape optimal design is to create a design model by parameterizing a geometric model. Shape design parameterization is more complicated and difficult to handle than sizing design parameterization. First, the optimum shape is highly dependent on the design parameterization selected. An inappropriate design parameterization may result in an impractical design. On the other hand, changing the geometric shape of the design model to reflect successive changes in design parameters is a tedious, complicated, and inefficient process. Manual updates of geometric shape and finite element meshes are quite impractical. In this paper, a shape design parameterization method that is built on the geometric modeler PATRAN is presented. Using this method, a number of geometric entities that represent structural design boundaries are parameterized, and a design parameter linking process can be performed to create geometric features from geometric entities. To support the ...

Probabilistic Structural Durability Prediction

Anefe cientreliability analysis method fordurability of structural components subjected to external and inertial loads with time-dependent variable amplitudes is presented. This method is able to support reliability analysis of crack-initiation and crack-propagation lives of practical applications, considering uncertainties such as material properties, manufacturing tolerances, and initial crack size. Three techniques are employed to support the probabilistic durability prediction: 1 ) strain-based approach for multiaxial crack-initiation-life prediction and linear elastic fracture mechanics approach for crack-propagation-life prediction, 2 ) statistics-based approach for reliability analysis, and 3 ) sensitivity analysis and optimization methods for searching the most probable point (MPP) in the random variable space to compute the fatigue failure probability using the e rst-order reliability analysis method. A two-point approximation method is employed to speed up the MPP search. A tracked-vehicle roadarm is presented to demonstrate feasibility of the proposed method.

DESIGN SENSITIVITY ANALYSIS AND OPTIMIZATION TOOL (DSO) FOR SHAPE DESIGN APPLICATIONS

The Design Sensitivity Analysis and Optimization (DSO) tool, developed initially for sizing design application, has been extended to support shape design applications of structural components. The new capabilities including shape design parameterization, error analysis and mesh adaptation, design velocity field computation, shape design sensitivity analysis, and interactive design steps, are discussed. These capabilities are integrated on the top of the DSO framework that includes databases, user interface, foundation class and remote module. The DSO allows the design engineer to easily create geometric, design, and analysis models; define performance measures; perform design sensitivity analysis (DSA); and carry out a four-step interactive design process that includes visual display of design sensitivity, what-if study, trade-off analysis, and interactive design optimization. Additionally, a 3-D tracked vehicle clevis is presented in this paper to demonstrate the new capabilities.

Integration of design and manufacturing for structural shape optimization

Abstract This paper presents an integrated design and manufacturing approach that supports shape optimization of structural components. The approach starts from a primitive concept stage, where boundary and loading conditions of the structural component are given to the designer. Topology optimization is conducted for an initial structural layout. The discretized structural layout is smoothed using parametric B-Spline surfaces. The B-Spline surfaces are imported into a CAD system to construct parametric solid models for shape optimization. Virtual manufacturing (VM) techniques are employed to ensure that the optimized shape can be manufactured at a reasonable cost. The solid freeform fabrication (SFF) system fabricates physical prototypes of the structure for design verification. Finally, a computer numerical control (CNC) machine is employed to fabricate functional parts as well as mold or die for mass production of the structural component. The main contribution of the paper is incorporating manufacturing into the design process, where manufacturing cost is considered for design. In addition, the overall design process starts from a primitive stage and ends with functional parts. A 3D tracked vehicle roadarm is employed throughout this paper to illustrate the overall design process and various techniques involved.

Design parameterization and tool integration for CAD-based mechanism optimization

Abstract This paper presents an open and integrated tool environment that enables engineers to effectively search, in a CAD solid model form, for a mechanism design with optimal kinematic and dynamic performance. In order to demonstrate the feasibility of such an environment, design parameterization that supports capturing design intents in product solid models must be available, and advanced modeling, simulation, and optimization technologies implemented in engineering software tools must be incorporated. In this paper, the design parameterization capabilities developed previously have been applied to support design optimization of engineering products, including a High Mobility Multi-purpose Wheeled Vehicle (HMMWV). In the proposed environment, Pro/ENGINEER and SolidWorks are supported for product model representation, DADS (Dynamic Analysis and Design System) is employed for dynamic simulation of mechanical systems including ground vehicles, and DOT (Design Optimization Tool) is included for a batch mode design optimization. In addition to the commercial tools, a number of software modules have been implemented to support the integration; e.g., interface modules for data retrieval, and model update modules for updating CAD and simulation models in accordance with design changes. Note that in this research, the overall finite difference method has been adopted to support design sensitivity analysis.

Concurrent Design and Manufacturing for Mechanical Systems

The conventional product development process employs a design-build-break philosophy. The sequentially executed product development process often results in a prolonged lead-time and an elevated product cost. The proposed concurrent design and manu facturing (CDM) paradigm employs physics-based computational methods together with computer graphics techniques for product de sign. This proposed approach employs Virtual Prototyping (VP) technology to support a cross-functional team in analyzing product per formance, reliability, and manufacturing cost early in the product development stage; and in conducting quantitative trade-off for design decision making. Physical prototypes of the product design are then produced using Rapid Prototyping (RP) technique primarily for de sign verification purposes. The proposed CDM approach holds potential for shortening the overall product development cycle, improving product quality, and reducing product cost. A software tool environment that supports CDM for mechanical systems is being built at the Concurrent Design and Manufacturing Research Laboratory (http://cdm.ou.edu) at the University of Oklahoma. A snapshot of the envi ronment is illustrated using a two-stroke engine example. This paper presents three unique concepts and methods for product develop ment : (1) bringing product performance, quality, and manufacturing cost together in early design stage for design considerations, (2) supporting design decision-making through a quantitative approach, and (3) incorporating rapid prototyping for design verification through physical prototypes.

Design sensitivity analysis of hyperelastic structures using a meshless method

A continuum-based design sensitivity analysis method for hyperelastic structures is presented. Analysis is performed using a meshless method, called the reproducing kernel particle method. Yeoh’ s energy density function is used to describe thehyperelastic structural behavior. The meshless method eliminates mesh distortion orentanglement encountered in using e nite element analysis for large deformation structural analysis and structural shape design optimization. Both the adjoint variable and direct differentiation methods are developed for material and shape design variables. An ine nitely long rubber tube, a two-dimensional rubber band, and an engine mount are examples used to demonstrate the feasibility and accuracy of the method.

SHAPE DESIGN SENSITIVITY ANALYSIS AND OPTIMIZATION FOR STRUCTURAL DURABILITY

SUMMARY In this paper, a design sensitivity analysis (DSA) method for fatigue life of 3-D solid structural components of mecanical systems with respect to shape design parameters is presented. The DSA method uses dynamic stress DSA obtained using an analytical approach to predict dynamic stress increment due to design changes; computes fatigue life of the component, including crack initiation and crack propagation, using the predicted dynamic stress; and uses the di⁄erence of the new life and the original life at the same critical point to approximate the sensitivity of fatigue life. A tracked vehicle roadarm is presented in this paper to demonstrate accuracy and eƒciency of the DSA method. Also, this method is applied to support design optimization of the tracked vehicle roadarm considering crack initiation lives as design constraints. ( 1997 by John Wiley & Sons, Ltd.