Search NASA⌕ Search

Engineering topics

Watts, Seth

Publications and source records attributed to Watts, Seth.

14 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Response tailoring of elasto-plastic trusses

Abstract In this work we tailor the response of trusses loaded beyond their yield limit. The truss structures are modeled using finite strain theory and rate-independent elasto-plasticity. We design trusses with a tailored mechanical response that is between “elastic” and “elastic-ideal-plastic” subject to the volume constraint. The design updates are generated by the gradient-based Method of Moving Asymptotes (MMA) solver and the sensitivities of the response functions are computed using a path-dependent adjoint sensitivity analysis. The computations are performed in Matlab.

42 ENGINEERING↗
DOE OSTI2023

Yet another parameter-free shape optimization method

The use of node coordinates as design variables in shape optimization offers a larger design space than computer-aided design (CAD)-based shape parameterizations. It also allows for the optimization of legacy designs, i.e., a finite element mesh from an existing design can be readily optimized to meet new performance requirements without involving a CAD model. However, it is well known that the node coordinate parameterization method is fraught with numerical difficulties, which makes it impractical to use. This has led to several of “parameter-free” shape optimization methods that seek the advantages and avoid the pitfalls of the naïve node coordinate parameterization method. These methods come in two main varieties: sensitivity filtering (or gradient smoothing) and consistent filtering. The latter is analogous to the density filter method used in topology optimization (TO). In this work, we use the PDE filter from TO and energy-based filters to implement consistent shape optimization filtering schemes easily and efficiently. Numerical experiments demonstrate that consistent methods are more robust than sensitivity filtering methods.

42 ENGINEERING↗
DOE OSTI2023

Topology optimization of compliant mechanisms under transient thermal conditions

This work considers multi-material topology optimization of compliant mechanisms under transient thermal and quasi-static mechanical conditions wherein thermally actuated devices are optimized for different operating conditions. The materials are modeled using finite strain thermo-hyperelasticity and a two way coupling between the energy balance and equilibrium equations is investigated. The design updates are generated from the gradient-based method of moving asymptotes optimizer and the sensitivities are computed using the time dependent adjoint sensitivity analysis. Results show the impact of designing for short versus long actuation times.

42 ENGINEERING↗
DOE OSTI2023

Computational design of metamaterials with self contact

Inverse homogenization in combination with contact modeling, topology optimization and shape optimization is used to design metamaterials with optimized macroscopic response. The homogenization assumes length scale separation which allows the non-linear macroscopic behavior to be obtained by analyzing a single unit cell in a lattice structure. Self contact in the unit cell, which is modeled using a third medium contact method, is leveraged to obtain a complex homogenized response. The inverse homogenization problem is initially formulated as a topology optimization problem, where the macroscopic stress–strain behavior is tuned to our liking. However, it is well known that boundary phenomena are difficult to model in topology optimization and that interface modeling is crucial to accurately analyze contact. For that reason, the boundary representation of the topology optimized design is extracted and used as initial design in a subsequent shape optimization. The behaviors of our designs are verified by performing rigorous post-processing analyzes using conforming meshes and conventional contact formulations.

42 ENGINEERING↗
DOE OSTI2023

Stress‐constrained topology optimization of structures subjected to nonproportional loading

Abstract This work considers the topology optimization of hyperelastic structures for maximum stiffness (minimum compliance) subject to constraints on their volume and maximum stress. In contrast to almost all previous works, we subject the structures to nonproportional loading, wherein the maximum stress does not necessarily occur at the final load step. As such, the stress is constrained at each load step. The augmented Lagrangian method is used to formulate the optimization problem with its many constraints. In numerical examples, we investigate different load trajectories for the same terminal load and compare the optimized designs and their performances. The results show the importance of considering the entire load trajectory as the load history significantly influences the optimized designs.

42 ENGINEERING↗
DOE OSTI2020

Simultaneous material, shape and topology optimization

Using three design fields we develop an optimization environment that can simultaneously optimize material, shape and topology. We use the implicit representation of the boundaries with level-set functions that define the shape and topology. Differentiable R-functions allow us to combine these shapes and topology descriptions with Boolean operations. Additionally, we incorporate design dependent-stiffness materials with another design field. Notably, this framework accommodates design dependent loads, has the ability to introduce holes, and ensures the satisfaction of optimality criteria. It builds upon the fictitious domain, ersatz material, material interpolation and level-set methods. Additionally, it also borrows from parameterized density-based topology optimization methods. Since analytical sensitivities can be computed, we use efficient nonlinear programming algorithms to update the design instead of the Hamilton–Jacobi’s scheme of level-set methods. We illustrate the features of our framework by designing a cantilever beam with octet truss microlattice, a dam with design-dependent loads, and a composite clevis plate.

42 ENGINEERING↗
DOE OSTI2019

Stiff isotropic lattices beyond the Maxwell criterion

Materials with a stochastic microstructure, like foams, typically exhibit low mechanical stiffness, whereas lattices with a designed microarchitecture often show notably improved stiffness. These periodic architected materials have previously been designed by rule, using the Maxwell criterion to ensure that their deformation is dominated by the stretching of their struts. Classical designs following this rule tend to be anisotropic, with stiffness depending on the load orientation, but recently, isotropic designs have been reported by superimposing complementary anisotropic lattices. We have designed stiff isotropic lattices de novo with topology optimization, an approach based on continuum finite element analysis. Here, we present results of experiments on these lattices, fabricated by additive manufacturing, that validate predictions of their performance and demonstrate that they are as efficient as those designed by rule, despite appearing to violate the Maxwell criterion. These results highlight the enhanced potential of topology optimization to design materials with unprecedented properties.

42 ENGINEERING↗
DOE OSTI2019

Simple, accurate surrogate models of the elastic response of three-dimensional open truss micro-architectures with applications to multiscale topology design

Elastic meta-materials are those whose unique properties come from their micro-architecture, rather than, e.g., from their chemistry. The introduction of such architecture, which is increasingly able to be fabricated due to advances in additive manufacturing, expands the design domain and enables improved design, from the most complex multi-physics design problems to the simple compliance design problem that is our focus. Unfortunately, concurrent design of both the micro-scale and the macroscale is computationally very expensive when the former can vary spatially, particularly in three dimensions. Instead, we provide simple, accurate surrogate models of the homogenized linear elastic response of the isotruss, the octet truss, and the ORC truss based on high-fidelity continuum finite element analyses. These surrogate models are relatively accurate over the full range of relative densities, in contrast to analytical models in the literature, which we show lose accuracy as relative density increases. The surrogate models are also simple to implement, which we demonstrate by modifying Sigmund’s 99-line code to solve a three-dimensional, multiscale compliance design problem with spatially varying relative density. Here, we use this code to generate examples in both two and three dimensions that illustrate the advantage of elastic meta-materials over structures with a single length scale, i.e., those without micro-architectures.

42 ENGINEERING↗
DOE OSTI2018

Matlab Code for Multiscale Topology Optimization

This Matlab script implements a simple topology optimization algorithm that minimizes the compliance of a structure within a 3D prismatic design domain. It uses a simple linear elastic finite element solver to solve the equilibrium equations, and the optimality criterion (00) method to update the design iteratively. This functionality is identical to, or the simplest possible extension from 2D to 3D of, a 99-line Matlab code released in 2001 in a journal article by Sigmund. What is new in this code is our implementation of simple surrogate models for several truss micro-architectures, which converts this code to a multiscale design tool, whereas the original code is single-scale. The development of these surrogate models and their implementation is described in a journal article we intend to submit. We plan to include the full source code in an Appendix in this paper. The code’s primary function is as a pedagogical tool rather than as a finished software product. Sigmund’s 2001 paper describes the implementation line-by-line. We are including this updated version of the code to allow the reader to understand exactly what changes must be made to a “standard” topology optimization code to implement the surrogate models and thus multiscale design optimization.

Watts, Seth↗
DOE OSTI2017

Data Sciences Summer Institute Topology Optimization

DSSI_TOPOPT is a 2D topology optimization code that designs stiff structures made of a single linear elastic material and void space. The code generates a finite element mesh of a rectangular design domain on which the user specifies displacement and load boundary conditions. The code iteratively designs a structure that minimizes the compliance (maximizes the stiffness) of the structure under the given loading, subject to an upper bound on the amount of material used. Depending on user options, the code can evaluate the performance of a user-designed structure, or create a design from scratch. Output includes the finite element mesh, design, and visualizations of the design.

Watts, Seth↗
DOE OSTI2017

A geometric projection method for designing three-dimensional open lattices with inverse homogenization

Topology optimization is a methodology for assigning material or void to each point in a design domain in a way that extremizes some objective function, such as the compliance of a structure under given loads, subject to various imposed constraints, such as an upper bound on the mass of the structure. Geometry projection is a means to parameterize the topology optimization problem, by describing the design in a way that is independent of the mesh used for analysis of the design's performance; it results in many fewer design parameters, necessarily resolves the ill-posed nature of the topology optimization problem, and provides sharp descriptions of the material interfaces. We extend previous geometric projection work to 3 dimensions and design unit cells for lattice materials using inverse homogenization. We perform a sensitivity analysis of the geometric projection and show it has smooth derivatives, making it suitable for use with gradient-based optimization algorithms. The technique is demonstrated by designing unit cells comprised of a single constituent material plus void space to obtain light, stiff materials with cubic and isotropic material symmetry. Here, we also design a single-constituent isotropic material with negative Poisson's ratio and a light, stiff material comprised of 2 constituent solids plus void space.

42 ENGINEERING↗
DOE OSTI2016

An n -material thresholding method for improving integerness of solutions in topology optimization

It is common in solving topology optimization problems to replace an integer-valued characteristic function design field with the material volume fraction field, a real-valued approximation of the design field that permits "fictitious" mixtures of materials during intermediate iterations in the optimization process. This is reasonable so long as one can interpolate properties for such materials and so long as the final design is integer valued. For this purpose, we present a method for smoothly thresholding the volume fractions of an arbitrary number of material phases which specify the design. This method is trivial for two-material design problems, for example, the canonical topology design problem of specifying the presence or absence of a single material within a domain, but it becomes more complex when three or more materials are used, as often occurs in material design problems. We take advantage of the similarity in properties between the volume fractions and the barycentric coordinates on a simplex to derive a thresholding, method which is applicable to an arbitrary number of materials. As we show in a sensitivity analysis, this method has smooth derivatives, allowing it to be used in gradient-based optimization algorithms. Finally, we present results, which show synergistic effects when used with Solid Isotropic Material with Penalty and Rational Approximation of Material Properties material interpolation functions, popular methods of ensuring integerness of solutions.

42 ENGINEERING↗