Multidomain Topology Optimization for Structural and Material Designs

A multidomain topology optimization technique (MDTO) is developed, which extends the standard topology optimization method to the realm of more realistic engineering design problems. The new technique enables the effective design of a complex engineering structure by allowing the designer to control the material distribution among the subdomains during the optimal design process, to use multiple materials or composite materials in the various subdomains of the structure, and to follow a desired pattern or tendency for the material distribution. A new algorithm of Sequential Approximate Optimization (SAO) is proposed for the multidomain topology optimization, which is an enhancement and a generalization of previous SAO algorithms (including Optimality Criteria and Convex Linearization methods, etc.). An advanced substructuring method using quasi-static modes is also introduced to condense the nodal variables associated with the multidomain topology optimization problem, especially for the nondesign subdomains. The effectiveness of the new MDTO approach is demonstrated for various design problems, including one of “structure-fixture simultaneous design,” one of “functionally graded material design,” and one of “crush energy management.” These case studies demonstrate the potential significance of the new capability developed for a wide range of engineering design problems.