The focus of this research is on the development of a novel multi-disciplinary design optimization scheme for micro-compliant devices. Topology optimization is a powerful tool that can address the need for a systematic method to design MEMS. It is expected that systematic design methods will make the design of micro devices transparent to the user and thus spur their use. Although topology optimization of MEMS devices with embedded actuation has received a great deal of attention among researchers recently, there is not a significant amount of literature available on the subject. The limited literature available addresses multi-physics topology optimization, which employs the homogenization method. However, the products of this method inherit the drawbacks of homogenized material discretization, including checkerboard pattern, gray-scale material and narrow flexural hinges in the optimum solution. In this thesis, a new topology optimization scheme is introduced that addresses the specific needs of MEMS domain. A new discretization approach with frame-ground structure is introduced. This approach offers significant conceptual and practical advantages to the compliant MEMS optimization problem, including compatibility with MEMS fabrication processes. The design spaces of compliant mechanisms are non-convex and it is critical to employ an algorithm capable of converging to the global optimum without the need to evaluate gradients of objective function. In this thesis, an efficient real-coded genetic algorithm is implemented, which shows a better repeatability and converges to very similar solutions in different runs. This new method of optimization facilitates the use of a coarse subdivision of the design domain rather than the homogenized material method, for the same resolution of shape definition. Therefore, the topology optimization scheme developed in this thesis significantly reduces the computational burden without compromising the sharpness of the shape definition. As the problem of compliant mechanism design is posed as a set of conflicting objectives, a well-posed multi-criteria objective function is introduced which avoids one objective dominating the solution. Moreover, the formulation is modified to incorporate electro-thermal boundaries and enables the optimization of the compliant mechanisms to transfer maximum motion or maximum force at the output. A number of design examples are used to demonstrate the ability of the procedure to generate non-intuitive topologies. Their performance is verified using ANSYS and compared with results from the homogenization method and designs reported in the available literature.

The focus of this research is on the development of a novel multi-disciplinary design optimization scheme for micro-compliant devices. Topology optimization is a powerful tool that can address the need for a systematic method to design MEMS. It is expected that systematic design methods will make the design of micro devices transparent to the user and thus spur their use. Although topology optimization of MEMS devices with embedded actuation has received a great deal of attention among researchers recently, there is not a significant amount of literature available on the subject. The limited literature available addresses multi-physics topology optimization, which employs the homogenization method. However, the products of this method inherit the drawbacks of homogenized material discretization, including checkerboard pattern, gray-scale material and narrow flexural hinges in the optimum solution. In this thesis, a new topology optimization scheme is introduced that addresses the specific needs of MEMS domain. A new discretization approach with frame-ground structure is introduced. This approach offers significant conceptual and practical advantages to the compliant MEMS optimization problem, including compatibility with MEMS fabrication processes. The design spaces of compliant mechanisms are non-convex and it is critical to employ an algorithm capable of converging to the global optimum without the need to evaluate gradients of objective function. In this thesis, an efficient real-coded genetic algorithm is implemented, which shows a better repeatability and converges to very similar solutions in different runs. This new method of optimization facilitates the use of a coarse subdivision of the design domain rather than the homogenized material method, for the same resolution of shape definition. Therefore, the topology optimization scheme developed in this thesis significantly reduces the computational burden without compromising the sharpness of the shape definition. As the problem of compliant mechanism design is posed as a set of conflicting objectives, a well-posed multi-criteria objective function is introduced which avoids one objective dominating the solution. Moreover, the formulation is modified to incorporate electro-thermal boundaries and enables the optimization of the compliant mechanisms to transfer maximum motion or maximum force at the output. A number of design examples are used to demonstrate the ability of the procedure to generate non-intuitive topologies. Their performance is verified using ANSYS and compared with results from the homogenization method and designs reported in the available literature.

Structural topology optimization has been extensively studied in aeronautical, civil, and mechanical engineering applications in order to improve performance of systems. This thesis focuses on an optimal design of damping treatment using topology optimization, and the reduction of computational expense of the topology optimization procedure. This thesis presents mainly two works on topology optimization. In the first work, topology optimization is implemented to optimally design damping treatments in unconstrained-layer damping material. Since the damping effect relies on the placement of damping treatment, and the weight of damping material may be an important factor, the placement of damping material is optimally determined using topology optimization with an allowable maximum. Unconstrained-layer plate and shell structures are modeled. The damping layer on the unconstrained-layer structures is considered as the design domain. Using topology optimization, the damping layer is designed numerically, and then experimentally validated by comparing the damping effects. In the numerical example, the topological damping treatment usually provides much higher damping effects compared to other approaches such as strain energy distribution (SED) and an evolutionary structural optimization (ESO). In the second work, a numerical algorithm, named as reducible design variable method (RDVM) topology optimization, is proposed in order to efficiently reduce the computational expense. Since it usually requires thousands to millions of design variables and up to hundreds of iterations in topology optimization, the major difficulty is its computational expense. The RDVM topology optimization is implemented into static (minimization of compliance) and dynamic (maximization of the fundamental resonance frequency) problems. The RDVM significantly reduces computing time, as confirmed by numerical examples. / Thesis (Ph.D, Mechanical and Materials Engineering) -- Queen's University, 2011-07-08 10:10:20.606

Under-running of passenger vehicle is one of the major parameters to be considered during the design and development of truck chassis. Front Under-run Protection Device (FUPD) plays an important role in avoiding under-running of vehicles from front side of a truck. This thesis is used to develop additional device which stops the impact from frontal area, which will not allow the passenger car inside the truck. The complete thesis was started from an idea of adding FUPD to truck chassis. Design of FUPD is done using 3D CAD software CATIA V5R20, then complete FUPD assembly is imported and done pre-processing using Altair Hyper Mesh, for visualizing the results. Crash analysis is done using Altair Radioss & results interpretation is done using HyperView and Hypergraph. FUPD is designed based on ECE R93 which satisfies the failure criteria (Standard) of displacement less than 400 mm. An Initial Design is generated along with Holding Brackets as an assembly using CATIA V5 as a tool. Base design is further optimized for getting light weight structure that meets structural performance criteria. By assuming all the loading conditions as per the standards, an amount of 27% mass reduction is obtained in FUPD Assembly along with holding bracket.

Peridynamics (PD), a reformulation of the Classical Continuum Mechanics (CCM), is a new and promising meshless and nonlocal computational method in solid mechanics. To permit discontinuities, the PD integro-differential equation contains spatial integrals and time derivatives. PD can be considered as the continuum version of molecular dynamics. This feature of PD makes it a good candidate for multi-scale analysis of materials. Concurrently, the topology optimization has also been rapidly growing in view of the need to design lightweight and high performance structures. Therefore, this thesis presents the potential for a peridynamics-based topology optimization approach. To avoid the gradient calculations, a heuristic topology optimization method is employed. The minimization of the PD strain energy density is set as the objective function. The structure is optimized based on a modified solid isotropic material with a penalization approach and a projection scheme is utilized to obtain distinct results. Several test cases have been studied to analyze the suitability of the proposed method in topology optimization. / Graduate

Orientador: Renato Pavanello / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-27T18:05:36Z (GMT). No. of bitstreams: 1 QuispeRodriguez_Sergio_M.pdf: 51003475 bytes, checksum: 7e557fe0fe0448fd7cae415ebca527f8 (MD5) Previous issue date: 2015 / Resumo: A otimização estrutural topológica é uma ferramenta aplicada atualmente em muitos campos da engenharia tendo se consolidado no meio acadêmico e industrial. Em muitos casos práticos os carregamentos mecânicos e térmicos ocorrem simultaneamente nas estruturas. Nestas situações, a aplicação do método de otimização estrutural topológica deve contemplar tanto os requisitos mecânicos, como os requisitos térmicos. Assim, uma abordagem multi-física e multi-objetivo precisa ser desenvolvida para a solução desta classe de problemas. O presente trabalho é dedicado ao estudo da aplicação do método BESO (BESO - Bi-directional Evolutionary Structural Optimization) à sistemas multi-físicos considerando inicialmente os carregamentos termo-mecânicos como forças de corpo ou seja, forças dependentes do projeto. As funções objetivo consideradas são a flexibilidade média da estrutura e a capacidade térmica do sistema. A análise termo-mecânica é realizada usando o método de acoplamento sequencial, onde obtêm-se inicialmente a resposta do campo térmico, ou aplica-se um campo previamente conhecido do ponto da estrutura e na sequência calculam-se as forças térmicas geradas e a dilatação da estrutura. Explora-se também a otimização termo-mecânica multiobjetivo, em que duas funções objetivo são consideradas simultaneamente. Considera-se como o objetivo do problema de otimização, a minimização da flexibilidade média e a minimização da capacidade térmica, usando o método de soma ponderada. Para a validação dos procedimentos de otimização implementados neste trabalho, são apresentados exemplos de otimização para sistemas termo-mecânicos bidimensionais. A viabilidade do método para aplicação em problemas de engenharia e a comparação de resultados com outros métodos de otimização, permite afirmar que as técnicas propostas podem ser usadas na solução de problemas de otimização topológica de sistemas termo-mecânicos / Abstract: The structural topology optimization is an usefull tool applied in many engineering fields, having been established in the academic and industrial environments. In many practical cases, the mechanical and thermal loads occur simultaneously in a structure. In these cases, the aplication of structural topology optimization should consider the thermal and mechanical requirements. For this reason, a multi-physic and multi-objective approach needs to be developed for the solution of these types of problems. The present work is dedicated to the study of the BESO method (BESO - Bi-directional Evolutionary Structural Optimization) applied to multi-physic systems taking in consideration thermo-mechanical loads as design dependent body loads. The objective functions considered are the compliance and heat capacity of the system. The thermo-mechanical analysis is carried out using a sequential coupling method, where the thermal field response is obtained initially, and in the sequence, the thermal loads or dilation loads are calculated. The bi-objective thermo-mechanical optimization problem is also analysed, where two objective functions are considered simultaneously. To validate the procedures implemented in this work, some 2-D examples of thermo-mechancial systems optimization are presented. The feasibility of the method for the aplication in engineering problems and the comparison of the results obtained using other methods, alows to state that the proposed techniques can be used in the solution of optimization problems of thermo-mechanical systems / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica

京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第21752号 / 工博第4569号 / 新制||工||1712(附属図書館) / 京都大学大学院工学研究科機械理工学専攻 / (主査)教授 西脇 眞二, 准教授 泉井 一浩, 教授 椹木 哲夫, 教授 松原 厚 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

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Improving the design of flow channels in a liquid-cooled heat sink is critical for boosting the capabilities of electronic components as well as reducing energy usage by the pump. This work explores the use of topology optimization to minimize the pressure difference across a heat sink and consequently, the energy used to supply the liquid. Topology optimization involves solving mathematical equations to obtain the optimal design for a defined cost function, here the total pressure difference between the inlet and outlet. A design variable called the porosity is defined for each cell in the mesh. The porosity features in a sink term in the momentum equation, which 'solidifies' cells by velocity suppression when deemed to be counterproductive to the cost function. The adjoint method of topology optimization, in particular, is a well-established tool for use in flow network problems and includes non-physical parameters such as the adjoint velocity and pressure. The method isn't without its drawbacks, such as the numerical instability of the adjoint equations, and the absence of boundary layers or wall functions at the interface of high and low porosity. The strength of the adjoint method lies in the ease with which it calculates the gradient of the cost function with respect to the porosity. When applied to the geometries in this work, it is observed that the problem is non-convex and results in multiple optimums with similar cost values. Thus the objective becomes seeking solutions with the simplest shape and at the same time having a minimized pressure difference. Interesting techniques are tested, namely an interpolation function, a velocity tolerance, and a volume constraint. The work is accomplished by modifying an existing adjoint optimization solver in the open-source CFD software, OpenFOAM.