This thesis consists of an introduction and sevenindependent, but closely related, papers which all deal withproblems in structural optimization. In particular, we considermodels and methods for global optimization of problems intopology design of discrete and continuum structures. In the first four papers of the thesis the nonconvex problemof minimizing the weight of a truss structure subject to stressconstraints is considered. First itis shown that a certainsubclass of these problems can equivalently be cast as linearprograms and thus efficiently solved to global optimality.Thereafter, the behavior of a certain well-known perturbationtechnique is studied. It is concluded that, in practice, thistechnique can not guarantee that a global minimizer is found.Finally, a convergent continuous branch-and-bound method forglobal optimization of minimum weight problems with stress,displacement, and local buckling constraints is developed.Using this method, several problems taken from the literatureare solved with a proof of global optimality for the firsttime. The last three papers of the thesis deal with topologyoptimization of discretized continuum structures. Theseproblems are usually modeled as mixed or pure nonlinear 0-1programs. First, the behavior of certain often usedpenalization methods for minimum compliance problems isstudied. It is concluded that these methods may fail to producea zero-one solution to the considered problem. To remedy this,a material interpolation scheme based on a rational functionsuch that compli- ance becomes a concave function is proposed.Finally, it is shown that a broad range of nonlinear 0-1topology optimization problems, including stress- anddisplacement-constrained minimum weight problems, canequivalently be modeled as linear mixed 0-1 programs. Thisresult implies that any of the standard methods available forgeneral linear integer programming can now be used on topologyoptimization problems. <b>Keywords:</b>topology optimization, global optimization,stress constraints, linear programming, mixed integerprogramming, branch-and-bound.

Main objective of this study is to design a compliant mechanism with high frequency and high mechanical amplification ratio to be used for amplifying the stroke of a piezostack actuator. In this thesis, first of all, related literature is investigated and then alternative conceptual designs are established utilizing the mechanisms found in literature survey. Once best conceptual design is selected, detailed design of this mechanism is done. For detailed design of the compliant mechanism, topology optimization method is used in this study. To design the mechanism, first a design domain is defined and then a finite element model of the design domain is prepared to be used in topology optimization runs. After running the topology optimization model by using TOSCA with ANSYS, results are imported to ANSYS, where final performance of the mechanism design is checked. After finalizing design of the mechanism, it is produced and its performance is tested through experiments.

Main objective of this study is to design a compliant mechanism with high frequency and high mechanical amplification ratio to be used for amplifying the stroke of a piezostack actuator. In this thesis, first of all, related literature is investigated and then alternative conceptual designs are established utilizing the mechanisms found in literature survey. Once best conceptual design is selected, detailed design of this mechanism is done. For detailed design of the compliant mechanism, topology optimization method is used in this study. To design the mechanism, first a design domain is defined and then a finite element model of the design domain is prepared to be used in topology optimization runs. After running the topology optimization model by using TOSCA with ANSYS, results are imported to ANSYS, where final performance of the mechanism design is checked. After finalizing design of the mechanism, it is produced and its performance is tested through experiments.

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Vibration control is inevitable in many fields, including mechanical and civil engineering. This matter becomes more crucial for lightweight systems, like those made of magnesium. One of the most commonly practiced methods in vibration control is to apply constrained layer damping (CLD) patches to the surface of a structure. In order to consider the weight efficiency of the structure, the best shape and locations of the patches should be determined to achieve the optimum vibration suppression with the lowest amount of damping patch. In most research work done so far, the shape of patches are assumed to be known and only their optimum locations are found. However, the shape of the patches plays an important role in vibration suppression that should be included in the overall optimization procedure. In this research, a novel topology optimization approach is proposed. This approach is capable of finding the optimum shape and locations of the patches simultaneously for a given surface area. In other words, the damping optimization will be formulated in the context of the level set technique, which is a numerical method used to track shapes and locations concurrently. Although level set technique offers several key benefits, its application especially in time-varying problems is somewhat cumbersome. To overcome this issue, a unique programming technique is suggested that utilizes MATLAB© and COMSOL© simultaneously. Different 2D structures will be considered and CLD patches will be optimally located on them to achieve the highest modal loss factor. Optimization will be performed while having different amount of damping patches to check the effectiveness of the technique. In all cases, certain constraints are imposed in order to make sure that the amount of damping material remains constant and equal to the starting value. Furthermore, different natural frequencies will be targeted in the damping optimization, and their effects will also be explained. The level set optimization technique will then be expanded to 3D structures, and a novel approach will be presented for defining an efficient 4D level set function to initialize the optimization process. Vibrations of a satellite dish will be optimally suppressed using CLD patches. Dependency of the optimum shape and location of patches to different parameters of the models such as natural frequencies and initial starting point will be examined. In another practical example, excessive vibrations of an automotive dash panel will be minimized by adding damping materials and their optimal distribution will be found. Finally, the accuracy of the proposed method will be experimentally confirmed through lab tests on a rectangular plate with nonsymmetrical boundary conditions. Different damping configurations, including the optimum one, will be tested. It will be shown that the optimum damping configuration found via level set technique possesses the highest loss factor and reveals the best vibration attenuation. The proposed level set topology optimization method shows high capability of determining the optimum damping set in structures. The effective coding method presented in this research will make it possible to easily extend this method to other physical problems such as image processing, heat transfer, magnetic fields, etc. Being interconnected, the physical part will be modeled in a finite element package like COMSOL and the optimization advances by means of Hamilton-Jacobi partial differential equation. Thus, the application of the proposed method is not confined to damping optimization and can be expanded to many engineering problems. In summary, this research: - offers general solution to 2D and 3D CLD applications and simultaneously finds the best shape and location of the patches for a given surface area (damping material); - extends the level set technique to concurrent shape and location optimization; - proposes a new numerical implementation to handle level set optimization problems in any complicated structure; - makes it possible to perform level set optimization in time dependent problems; - extends level set approach to higher order problems.

A compliant mechanism gains its motion from the deflection of flexible members or the deformation of one portion of materials with respect to other portions. Design and operation of compliant mechanisms are very important, as most of the natural objects are made of compliant materials mixed with rigid materials, such as the bird wings. The most serious problem with compliant mechanisms is their fatigue problem due to repeating deformation of materials in compliant mechanisms. This thesis presents a study on the computational framework for designing a compliant mechanism under fatigue strength control. The framework is based on the topology optimization technique especially ground structure approach (GSA) together with the Genetic Algorithm (GA) technique. The study presented in this thesis has led to the following conclusions: (1) It is feasible to incorporate fatigue strength control especially the stress-life method in the computational framework based on the GSA for designing compliant mechanisms and (2) The computer program can well implement the computational framework along with the general optimization model and the GA to solve the model. There are two main contributions resulting from this thesis: First one is provision of a computational model to design compliant mechanisms under fatigue strength control. This model also results in a minimum number of elements of the compliant mechanism in design, which means the least weight of mechanisms and least amount of materials. Second one is an experiment for the feasibility of implementing the model in the MATLAB environment which is widely used for engineering computation, which implies a wide applicability of the design system developed in this thesis.

<p>This thesis consists of an introduction and sevenindependent, but closely related, papers which all deal withproblems in structural optimization. In particular, we considermodels and methods for global optimization of problems intopology design of discrete and continuum structures.</p><p>In the first four papers of the thesis the nonconvex problemof minimizing the weight of a truss structure subject to stressconstraints is considered. First itis shown that a certainsubclass of these problems can equivalently be cast as linearprograms and thus efficiently solved to global optimality.Thereafter, the behavior of a certain well-known perturbationtechnique is studied. It is concluded that, in practice, thistechnique can not guarantee that a global minimizer is found.Finally, a convergent continuous branch-and-bound method forglobal optimization of minimum weight problems with stress,displacement, and local buckling constraints is developed.Using this method, several problems taken from the literatureare solved with a proof of global optimality for the firsttime.</p><p>The last three papers of the thesis deal with topologyoptimization of discretized continuum structures. Theseproblems are usually modeled as mixed or pure nonlinear 0-1programs. First, the behavior of certain often usedpenalization methods for minimum compliance problems isstudied. It is concluded that these methods may fail to producea zero-one solution to the considered problem. To remedy this,a material interpolation scheme based on a rational functionsuch that compli- ance becomes a concave function is proposed.Finally, it is shown that a broad range of nonlinear 0-1topology optimization problems, including stress- anddisplacement-constrained minimum weight problems, canequivalently be modeled as linear mixed 0-1 programs. Thisresult implies that any of the standard methods available forgeneral linear integer programming can now be used on topologyoptimization problems.</p><p><b>Keywords:</b>topology optimization, global optimization,stress constraints, linear programming, mixed integerprogramming, branch-and-bound.</p>

<p>This thesis concerns the approximation of optimally controlled partial differential equations for applications in optimal design and reconstruction. Such optimal control problems are often ill-posed and need to be regularized to obtain good approximations. We here use the theory of the corresponding Hamilton-Jacobi-Bellman equations to construct regularizations and derive error estimates for optimal design problems. The constructed Pontryagin method is a simple and general method where the first, analytical, step is to regularize the Hamiltonian. Next its stationary Hamiltonian system, a nonlinear partial differential equation, is computed efficiently with the Newton method using a sparse Jacobian. An error estimate for the difference between exact and approximate objective functions is derived, depending only on the difference of the Hamiltonian and its finite dimensional regularization along the solution path and its<em> L</em>² projection, i.e. not on the difference of the exact and approximate solutions to the Hamiltonian systems. In the thesis we present solutions to applications such as optimal design and reconstruction of conducting materials and elastic structures.</p>

Vibration control is inevitable in many fields, including mechanical and civil engineering. This matter becomes more crucial for lightweight systems, like those made of magnesium. One of the most commonly practiced methods in vibration control is to apply constrained layer damping (CLD) patches to the surface of a structure. In order to consider the weight efficiency of the structure, the best shape and locations of the patches should be determined to achieve the optimum vibration suppression with the lowest amount of damping patch. In most research work done so far, the shape of patches are assumed to be known and only their optimum locations are found. However, the shape of the patches plays an important role in vibration suppression that should be included in the overall optimization procedure. In this research, a novel topology optimization approach is proposed. This approach is capable of finding the optimum shape and locations of the patches simultaneously for a given surface area. In other words, the damping optimization will be formulated in the context of the level set technique, which is a numerical method used to track shapes and locations concurrently. Although level set technique offers several key benefits, its application especially in time-varying problems is somewhat cumbersome. To overcome this issue, a unique programming technique is suggested that utilizes MATLAB© and COMSOL© simultaneously. Different 2D structures will be considered and CLD patches will be optimally located on them to achieve the highest modal loss factor. Optimization will be performed while having different amount of damping patches to check the effectiveness of the technique. In all cases, certain constraints are imposed in order to make sure that the amount of damping material remains constant and equal to the starting value. Furthermore, different natural frequencies will be targeted in the damping optimization, and their effects will also be explained. The level set optimization technique will then be expanded to 3D structures, and a novel approach will be presented for defining an efficient 4D level set function to initialize the optimization process. Vibrations of a satellite dish will be optimally suppressed using CLD patches. Dependency of the optimum shape and location of patches to different parameters of the models such as natural frequencies and initial starting point will be examined. In another practical example, excessive vibrations of an automotive dash panel will be minimized by adding damping materials and their optimal distribution will be found. Finally, the accuracy of the proposed method will be experimentally confirmed through lab tests on a rectangular plate with nonsymmetrical boundary conditions. Different damping configurations, including the optimum one, will be tested. It will be shown that the optimum damping configuration found via level set technique possesses the highest loss factor and reveals the best vibration attenuation. The proposed level set topology optimization method shows high capability of determining the optimum damping set in structures. The effective coding method presented in this research will make it possible to easily extend this method to other physical problems such as image processing, heat transfer, magnetic fields, etc. Being interconnected, the physical part will be modeled in a finite element package like COMSOL and the optimization advances by means of Hamilton-Jacobi partial differential equation. Thus, the application of the proposed method is not confined to damping optimization and can be expanded to many engineering problems. In summary, this research: - offers general solution to 2D and 3D CLD applications and simultaneously finds the best shape and location of the patches for a given surface area (damping material); - extends the level set technique to concurrent shape and location optimization; - proposes a new numerical implementation to handle level set optimization problems in any complicated structure; - makes it possible to perform level set optimization in time dependent problems; - extends level set approach to higher order problems.

Fatigue, or failure of material due to repeated cyclic loading, is one of the most common causes of mechanical failures. The risk of fatigue in a load carrying component is often lowered by adding material, thereby reducing stresses. This increases the component weight, reducing the performance of the component and increasing its manufacturing cost. There is thus a need to design components to be as light as possible, while keeping the risk of fatigue at a low enough level, i.e. there is a need for optimization of the component subject to fatigue constraints.  This thesis deals with design against fatigue using topology optimization, which is a form of structural optimization where an optimal design is sought by using mathematical programming to decide which parts of a design domain should be filled with material, and which should not.  To predict fatigue, accurate representation of the geometry and accurate stress computation are of utmost importance. In this thesis, methods for imposing constraints such as minimum inner radii and minimum member sizes in the form of four new density filters are proposed. The filters are able to generate a very sharp representation of the structural boundary. A method for improving the accuracy of stress results at the structural boundary is also proposed, based on extrapolation of results from the interior of the structure. The method gives more accurate stresses, which affects the resulting structures when solving optimization problems.  A formulation for fatigue constraints in topology optimization is proposed, based on the weakest link integral. The formulation avoids the problem of choosing between accurate but costly local constraints, and efficient but approximate aggregated constraints, and gives a theoretical motivation for using expressions similar to the p-norm of stresses.  For verifying calculations of the fatigue probability of an optimized structure, critical plane criteria are commonly used. A new method for evaluating such criteria using optimization methods is proposed, and is proved to give results within a user given error tolerance. It is shown that compared to existing brute force methods, the proposed method evaluates significantly fewer planes in the search of the critical one. / <p>QC 20150504</p>