Niels Aage

Topology optimisation for natural convection problems

This paper demonstrates the application of the density-based topology optimisation approach for the design of heat sinks and micropumps based on natural convection effects. The problems are modelled under the assumptions of steady-state laminar flow using the incompressible Navier-Stokes equations coupled to the convection-diffusion equation through the Boussinesq approximation. In order to facilitate topology optimisation, the Brinkman approach is taken to penalise velocities inside the solid domain and the effective thermal conductivity is interpolated in order to accommodate differences in thermal conductivity of the solid and fluid phases. The governing equations are discretised using stabilised finite elements and topology optimisation is performed for two different problems using discrete adjoint sensitivity analysis. The study shows that topology optimisation is a viable approach for designing heat sink geometries cooled by natural convection and micropumps powered by natural convection. Copyright c

Combined shape and topology optimization of 3D structures

We present a method for automatic generation of 3D models based on shape and topology optimization. The optimization procedure, or model generation process, is initialized by a set of boundary conditions, an objective function, constraints and an initial structure. Using this input, the method will automatically deform and change the topology of the initial structure such that the objective function is optimized subject to the specified constraints and boundary conditions. For example, this tool can be used to improve the stiffness of a structure before printing, reduce the amount of material needed to construct a bridge, or to design functional chairs, tables, etc. which at the same time are visually pleasing.The structure is represented explicitly by a simplicial complex and deformed by moving surface vertices and relabeling tetrahedra. To ensure a well-formed tetrahedral mesh during these deformations, the Deformable Simplicial Complex method is used. The deformations are based on optimizing the objective, which in this paper will be maximizing stiffness. Furthermore, the optimization procedure will be subject to constraints such as a limit on the amount of material and the difference from the original shape. Graphical abstractDisplay Omitted HighlightsAutomatic design of 3D structures given a set of requirements for that structure.Efficient shape and topology optimization utilizing an adaptive tetrahedral mesh.Explicit shape representation made possible by the Deformable Simplicial Complex method.

Large scale three-dimensional topology optimisation of heat sinks cooled by natural convection

Abstract This work presents the application of density-based topology optimisation to the design of three-dimensional heat sinks cooled by natural convection. The governing equations are the steady-state incompressible Navier–Stokes equations coupled to the thermal convection–diffusion equation through the Bousinessq approximation. The fully coupled non-linear multiphysics system is solved using stabilised trilinear equal-order finite elements in a parallel framework allowing for the optimisation of large scale problems with order of 20–330 million state degrees of freedom. The flow is assumed to be laminar and several optimised designs are presented for Grashof numbers between 10 3 and 10 6 . Interestingly, it is observed that the number of branches in the optimised design increases with increasing Grashof numbers, which is opposite to two-dimensional topology optimised designs. Furthermore, the obtained topologies verify prior conclusions regarding fin length/thickness ratios and Biot numbers, but also indicate that carefully tailored and complex geometries may improve cooling behaviour considerably compared to simple heat fin geometries.

Giga-voxel computational morphogenesis for structural design

In the design of industrial products ranging from hearing aids to automobiles and aeroplanes, material is distributed so as to maximize the performance and minimize the cost. Historically, human intuition and insight have driven the evolution of mechanical design, recently assisted by computer-aided design approaches. The computer-aided approach known as topology optimization enables unrestricted design freedom and shows great promise with regard to weight savings, but its applicability has so far been limited to the design of single components or simple structures, owing to the resolution limits of current optimization methods. Here we report a computational morphogenesis tool, implemented on a supercomputer, that produces designs with giga-voxel resolution—more than two orders of magnitude higher than previously reported. Such resolution provides insights into the optimal distribution of material within a structure that were hitherto unachievable owing to the challenges of scaling up existing modelling and optimization frameworks. As an example, we apply the tool to the design of the internal structure of a full-scale aeroplane wing. The optimized full-wing design has unprecedented structural detail at length scales ranging from tens of metres to millimetres and, intriguingly, shows remarkable similarity to naturally occurring bone structures in, for example, bird beaks. We estimate that our optimized design corresponds to a reduction in mass of 2–5 per cent compared to currently used aeroplane wing designs, which translates into a reduction in fuel consumption of about 40–200 tonnes per year per aeroplane. Our morphogenesis process is generally applicable, not only to mechanical design, but also to flow systems, antennas, nano-optics and micro-systems.

Infill Optimization for Additive Manufacturing—Approaching Bone-Like Porous Structures

Porous structures such as trabecular bone are widely seen in nature. These structures are lightweight and exhibit strong mechanical properties. In this paper, we present a method to generate bone-like porous structures as lightweight infill for additive manufacturing. Our method builds upon and extends voxel-wise topology optimization. In particular, for the purpose of generating sparse yet stable structures distributed in the interior of a given shape, we propose upper bounds on the localized material volume in the proximity of each voxel in the design domain. We then aggregate the local per-voxel constraints by their p-norm into an equivalent global constraint, in order to facilitate an efficient optimization process. Implemented on a high-resolution topology optimization framework, our results demonstrate mechanically optimized, detailed porous structures which mimic those found in nature. We further show variants of the optimized structures subject to different design specifications, and we analyze the optimality and robustness of the obtained structures.

Exploiting Additive Manufacturing Infill in Topology Optimization for Improved Buckling Load

ABSTRACT Additive manufacturing (AM) permits the fabrication of functionally optimized components with high geometrical complexity. The opportunity of using porous infill as an integrated part of the manufacturing process is an example of a unique AM feature. Automated design methods are still incapable of fully exploiting this design freedom. In this work, we show how the so-called coating approach to topology optimization provides a means for designing infill-based components that possess a strongly improved buckling load and, as a result, improved structural stability. The suggested approach thereby addresses an important inadequacy of the standard minimum compliance topology optimization approach, in which buckling is rarely accounted for; rather, a satisfactory buckling load is usually assured through a post-processing step that may lead to sub-optimal components. The present work compares the standard and coating approaches to topology optimization for the MBB beam benchmark case. The optimized structures are additively manufactured using a filamentary technique. This experimental study validates the numerical model used in the coating approach. Depending on the properties of the infill material, the buckling load may be more than four times higher than that of solid structures optimized under the same conditions.

Advanced Topology Optimization Methods for Conceptual Architectural Design

This paper presents a series of new, advanced topology optimization methods, developed specifically for conceptual architectural design of structures. The proposed computational procedures are implemented as components in the framework of a Grasshopper plugin, providing novel capacities in topological optimization: Interactive control and continuous visualization; embedding flexible voids within the design space; consideration of distinct tension / compression properties; and optimization of dual material systems. In extension, optimization procedures for skeletal structures such as trusses and frames are implemented. The developed procedures allow for the exploration of new territories in optimization of architectural structures, and offer new methodological strategies for bridging conceptual gaps between optimization and architectural practice.