16.810 (16.

682)
Engineering Design and Rapid Prototyping

Design Optimization
- Structural Design Optimization

Instructor(s)

Prof. Olivier de Weck Dr. Il Yong Kim

January 23, 2004

 Course Concept

today

16.810 (16.682) 2
 Course Flow Diagram
Learning/Review Problem statement Deliverables

Design Intro Hand sketching Design Sketch v1

CAD/CAM/CAE Intro CAD design Drawing v1

FEM/Solid Mechanics FEM analysis Analysis output v1

Overview
Manufacturing Produce Part 1 Part v1
Training
Structural Test Test Experiment data v1
“Training” today
Optimization Design/Analysis
Design Optimization
output v2
Wednesday
Produce Part 2 Part v2

Test Experiment data v2

Final Review
16.810 (16.682) 3
 What Is Design Optimization?

Selecting the “best” design within the available means

1. What is our criterion for “best” design? Objective function

2. What are the available means? Constraints

(design requirements)

3. How do we describe different designs? Design Variables

16.810 (16.682) 4
 Optimization Statement

Minimize f (x)
Subject to g (x) d 0
h( x) 0

16.810 (16.682) 5
 Constraints
- Design requirements

Inequality constraints

Equality constraints

16.810 (16.682) 6
 Objective Function
- A criterion for best design (or goodness of a design)

Objective function

16.810 (16.682) 7
 Design Variables

Parameters that are chosen to describe the design of a system

Design variables are “controlled” by the designers

The position of upper holes along the design freedom line

16.810 (16.682) 8
 Design Variables

For computational design optimization,

Objective function and constraints must be expressed

as a function of design variables (or design vector X)

Objective function: f (x) Constraints: g(x), h(x)

Cost = f(design)
Displacement = f(design)
What is “f” for each case?
Natural frequency = f(design)
Mass = f(design)

16.810 (16.682) 9
 Optimization Statement

Minimize f (x)
Subject to g (x) d 0
h( x) 0
f(x) : Objective function to be minimized
g(x) : Inequality constraints
h(x) : Equality constraints
x : Design variables

16.810 (16.682) 10
 Optimization Procedure
Minimize f (x)
Subject to g (x) d 0 START Determine an initial design (x0)
h( x) 0

Computer Simulation Evaluate f(x), g(x), h(x)

Improve Design

Change x

Converge ? Does your design meet a

N termination criterion?
Y

END

16.810 (16.682) 11
 Structural Optimization
Selecting the best “structural” design

- Size Optimization

- Shape Optimization

- Topology Optimization

16.810 (16.682) 12
 Structural Optimization

minimize f (x)
subject to g (x) d 0
h(x) 0

BC’s are given Loads are given

1. To make the structure strong Min. f(x)

e.g. Minimize displacement at the tip

2. Total mass d MC g(x) d 0

16.810 (16.682) 13
 Size Optimization

Beams
minimize f (x)
subject to g (x) d 0
h(x) 0

Design variables (x) f(x) : compliance

x : thickness of each beam g(x) : mass

Number of design variables (ndv)

ndv = 5

16.810 (16.682) 14
 Size Optimization

- Shape
are given
Topology
- Optimize cross sections

16.810 (16.682) 15
 Shape Optimization

B-spline
minimize f (x)
subject to g (x) d 0
h(x) 0

Hermite, Bezier, B-spline, NURBS, etc.

Design variables (x) f(x) : compliance

x : control points of the B-spline
g(x) : mass
(position of each control point)

Number of design variables (ndv)

ndv = 8
16.810 (16.682) 16
 Shape Optimization
Fillet problem Hook problem Arm problem

16.810 (16.682) 17
 Shape Optimization
Multiobjective & Multidisciplinary Shape Optimization
Objective function
1. Drag coefficient, 2. Amplitude of backscattered wave

Analysis
1. Computational Fluid Dynamics Analysis
2. Computational Electromagnetic Wave
Field Analysis

Obtain Pareto Front

Raino A.E. Makinen et al., “Multidisciplinary shape optimization in aerodynamics and electromagnetics using genetic
algorithms,” International Journal for Numerical Methods in Fluids, Vol. 30, pp. 149-159, 1999

16.810 (16.682) 18
 Topology Optimization

Cells
minimize f (x)
subject to g (x) d 0
h(x) 0

Design variables (x) f(x) : compliance

x : density of each cell g(x) : mass
Number of design variables (ndv)
ndv = 27

16.810 (16.682) 19
 Topology Optimization
Short Cantilever problem

Initial

Optimized

16.810 (16.682) 20
 Topology Optimization

16.810 (16.682) 21
 Topology Optimization
Bridge problem

Obj = 4.16u105

Distributed
loading

Obj = 3.29u105
Minimize ³ F i z i d*,
*

Subject to ³ U ( x ) d: d M o ,
:

0 d U (x) d 1 Obj = 2.88u105

Mass constraints: 35%

Obj = 2.73u105
16.810 (16.682) 22
 Topology Optimization
DongJak Bridge in Seoul, Korea

16.810 (16.682) 23
 Structural Optimization

What determines the type of structural optimization?

Type of the design variable

(How to describe the design?)

16.810 (16.682) 24
 Optimum Solution
– Graphical Representation

f(x): displacement
f(x)
x: design variable

x
Optimum solution (x*)

16.810 (16.682) 25
 Optimization Methods

Gradient-based methods

Heuristic methods

16.810 (16.682) 26
 Gradient-based Methods
You do not know this function before optimization
f(x)
Start
Check gradient

Move

Check gradient
Gradient=0 Stop!

x
No active constraints Optimum solution (x*)
(Termination criterion: Gradient=0)

16.810 (16.682) 27
 Gradient-based Methods

16.810 (16.682) 28
 Global optimum vs. Local optimum

f(x) Termination criterion: Gradient=0

Local optimum

Local optimum

Global optimum

x
No active constraints

16.810 (16.682) 29
 Heuristic Methods

„ A Heuristic is simply a rule of thumb that hopefully will find a

good answer.
„ Why use a Heuristic?
„ Heuristics are typically used to solve complex optimization
problems that are difficult to solve to optimality.
„ Heuristics are good at dealing with local optima without
getting stuck in them while searching for the global optimum.

Schulz, A.S., “Metaheuristics,” 15.057 Systems Optimization Course Notes, MIT, 1999.

16.810 (16.682) 30
 Genetic Algorithm

Principle by Charles Darwin - Natural Selection

16.810 (16.682) 31
 Heuristic Methods

„ Heuristics Often Incorporate Randomization

„ 3 Most Common Heuristic Techniques

„ Genetic Algorithms
„ Simulated Annealing
„ Tabu Search

16.810 (16.682) 32
 Optimization Software

- iSIGHT
- DOT
- Matlab (fmincon)

16.810 (16.682) 33
 Topology Optimization Software
™ ANSYS
Static Topology Optimization
Dynamic Topology Optimization
Electromagnetic Topology Optimization

Subproblem Approximation Method

First Order Method

Design domain

16.810 (16.682) 34
 Topology Optimization Software
™ MSC. Visual Nastran FEA

Elements of lowest stress are removed gradually.

Optimization results

Optimization results illustration

16.810 (16.682) 35
 MDO

Multidisciplinary Design Optimization

16.810 (16.682) 36
 Multidisciplinary Design Optimization
Centroid Jitter on Focal Plane [RSS LOS]
NASA Nexus Spacecraft Concept
60

40 1 pixel
T=5 sec

Centroid Y [Pm]
20

OTA 0
14.97 Pm
-20
Sunshield
Instrument -40
Module
Requirement: Jz,2=5 Pm
0 1 2 -60
-60 -40 -20 0 20 40 60
meters
Centroid X [Pm]

Goal: Find a “balanced” system design, where the flexible structure, the optics and the control systems work
together to achieve a desired pointing performance, given various constraints

16.810 (16.682) 37
 Multidisciplinary Design Optimization
Aircraft Comparison
Shown to Same Scale
Boeing Blended Wing Body Concept Approx. 480 passengers each
Approx. 8,700 nm range each

Operators 19%
BWB
Empty
A3XX-50R
Weight
Maximum 18%
BWB
Takeoff
A3XX-50R
Weight
Goal: Find a design for a family of blended wing aircraft
Total 19%
that will combine aerodynamics, structures, propulsion BWB
and controls such that a competitive system emerges - as Sea-Level
A3XX-50R
measured by a set of operator metrics. Static Thrust
Fuel 32%
BWB
Burn A3XX-50R
per Seat

16.810 (16.682) 38
 Multidisciplinary Design Optimization
Ferrari 360 Spider

Goal: High end vehicle shape optimization while

improving car safety for fixed performance level
and given geometric constraints

Reference: G. Lombardi, A. Vicere, H. Paap, G. Manacorda,

“Optimized Aerodynamic Design for High Performance Cars”, AIAA-98-
4789, MAO Conference, St. Louis, 1998

16.810 (16.682) 39
 Multidisciplinary Design Optimization

16.810 (16.682) 40
 Multidisciplinary Design Optimization

16.810 (16.682) 41
 Multidisciplinary Design Optimization
Do you want to learn more about MDO?

Take this course!

16.888/ESD.77

Multidisciplinary System
Design Optimization (MSDO)
Prof. Olivier de Weck
Prof. Karen Willcox

16.810 (16.682) 42
 Baseline Design

Performance

Natural frequency analysis

Design requirements

16.810 (16.682) 44
 Baseline Design

Performance and cost

G1 0.070 mm
G 2 0.011 mm
f 245 Hz
m 0.224 lbs
C 5.16 $

16.810 (16.682) 45
 Baseline Design

245 Hz 421 Hz

f1=245 Hz f1=0
f2=0
f2=490 Hz f3=0
f3=1656 Hz f4=0
f5=0
f6=0
f7=421 Hz
f8=1284 Hz
f9=1310 Hz

16.810 (16.682) 46
 Design Requirement for Each Team
Nat
Product mass Cost Disp Disp Qual F1 F2 F3
# Freq Const Optim Acc
name (m) (c) (G1) (G2) ity (lbs) (lbs) (lbs)
(f)

Base 0.224 5.16 0.070 0.011 245

0 3 50 50 100 c m G Gf
line lbs $ mm mm Hz

Family
1 20% -30% 10% 10% -20% 2 50 50 100 c m G Gf
economy

Family
2 10% -10% -10% -10% 10% 4 50 50 100 m c G Gf
deluxe

Cross
3 20% 0% -15% -15% 20% 4 50 75 75 m c G Gf
over

4 City bike -20% -20% 0% 0% 0% 3 50 75 75 c m G Gf

5 Racing -30% 50% 0% 0% 20% 5 100 100 50 m G G f c

6 Mountain 30% 30% -20% -20% 30% 4 50 100 50 G Gf m c

7 BMX 0% 65% -15% -15% 40% 4 75 100 75 G Gf m c

8 Acrobatic -30% 100% -10% -10% 50% 5 100 100 100 G Gf m c

Motor
9 50% 10% -20% -20% 0% 3 50 75 100 G Gf c m
bike

16.810 (16.682) 47
 Design Optimization
Topology optimization

Design domain

Shape optimization

16.810 (16.682) 48
 Design Freedom
1 bar
G 2.50 mm

G 2 bars
G 0.80 mm

Volume is the same.

17 bars
G 0.63 mm

16.810 (16.682) 49
 Design Freedom

1 bar

G 2.50 mm

2 bars

G 0.80 mm

17 bars
More design freedom More complex
(Better performance) (More difficult to optimize)

G 0.63 mm

16.810 (16.682) 50
 Cost versus Performance
17 bars

9
8
7
6 2 bars
Cost [$]

5 1 bar
4
3
2
1
0
0 0.5 1 1.5 2 2.5 3
Displacement [mm]

16.810 (16.682) 51
 Plan for the rest of the course
Class Survey
Jan 24 (Saturday) 7 am – Jan 26 (Monday) 11am

Company tour
Jan 26 (Monday) : 1 pm – 4 pm

Guest Lecture (Prof. Wilson, Bicycle Science)

Jan 28 (Wednesday) : 2 pm – 3:30 pm

Manufacturing Bicycle Frames (Version 2)

Jan 28 (Wednesday) : 9 am – 4:30 pm
Jan 29 (Thursday) : 9 am – 12 pm

Testing
Jan 29 (Thursday) : 10 am – 2 pm

GA Games
Jan 29 (Thursday) : 1 pm – 5 pm

Guest Lecture, Student Presentation (5~10 min/team)

Jan 30 (Friday) : 1 pm – 4 pm

16.810 (16.682) 52
 References

P. Y. Papalambros, Principles of optimal design, Cambridge University Press, 2000

O. de Weck and K. Willcox, Multidisciplinary System Design Optimization, MIT lecture note, 2003

M. O. Bendsoe and N. Kikuchi, “Generating optimal topologies in structural design using a

homogenization method,” comp. Meth. Appl. Mech. Engng, Vol. 71, pp. 197-224, 1988

Raino A.E. Makinen et al., “Multidisciplinary shape optimization in aerodynamics and

electromagnetics using genetic algorithms,” International Journal for Numerical Methods in Fluids,
Vol. 30, pp. 149-159, 1999

Il Yong Kim and Byung Man Kwak, “Design space optimization using a numerical design
continuation method,” International Journal for Numerical Methods in Engineering, Vol. 53, Issue 8,
pp. 1979-2002, March 20, 2002.

16.810 (16.682) 53
 Web-based topology optimization program

Developed and maintained by Dmitri Tcherniak, Ole Sigmund,

Thomas A. Poulsen and Thomas Buhl.

Features:

1.2-D
2.Rectangular design domain
3.1000 design variables (1000 square elements)
4. Objective function: compliance (FuG)
5. Constraint: volume

16.810 (16.682) 54
 Web-based topology optimization program

Objective function
-Compliance (FuG)

Constraint
-Volume

Design variables
- Density of each design cell

16.810 (16.682) 55
 Web-based topology optimization program

No numerical results are obtained.

Optimum layout is obtained.

16.810 (16.682) 56
 Web-based topology optimization program

P 2P 3P

Absolute magnitude of load does not affect optimum solution

16.810 (16.682) 57
 Web-based topology optimization program

http://www.topopt.dtu.dk

16.810 (16.682) 58