Publications

This report provides detailed documentation of the algorithms that where developed and implemented in the Plato software over the course of the Optimization-based Design for Manufacturing LDRD project.

This report provides detailed documentation of the algorithms that were developed and implemented in the Plato software over the course of the Optimization-based Design for Manufacturing LDRD project.

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This document is a summary of the mathematical models that are used in the DARPA TRADES project for the solid rocket motor design challenge. It is hoped that this brief description of these models will be of use to those that are working on the project.

We present a Matlab implementation of topology optimization for compliance minimization on unstructured polygonal finite element meshes that efficiently accommodates many materials and many volume constraints. Leveraging the modular structure of the educational code, PolyTop, we extend it to the multi-material version, PolyMat, with only a few modifications. First, a design variable for each candidate material is defined in each finite element. Next, we couple a Discrete Material Optimization interpolation with the existing penalization and introduce a new parameter such that we can employ continuation and smoothly transition from a convex problem without any penalization to a non-convex problem in which material mixing and intermediate densities are penalized. Mixing that remains due to the density filter operation is eliminated via continuation on the filter radius. To accommodate flexibility in the volume constraint definition, the constraint function is modified to compute multiple volume constraints and the design variable update is modified in accordance with the Zhang-Paulino-Ramos Jr. (ZPR) update scheme, which updates the design variables associated with each constraint independently. The formulation allows for volume constraints controlling any subset of the design variables, i.e., they can be defined globally or locally for any subset of the candidate materials. Borrowing ideas for mesh generation on complex domains from PolyMesher, we determine which design variables are associated with each local constraint of arbitrary geometry. A number of examples are presented to demonstrate the many material capability, the flexibility of the volume constraint definition, the ease with which we can accommodate passive regions, and how we may use local constraints to break symmetries or achieve graded geometries.

A framework is presented for multi-material compliance minimization in the context of continuum based topology optimization. We adopt the common approach of finding an optimal shape by solving a series of explicit convex (linear) approximations to the volume constrained compliance minimization problem. The dual objective associated with the linearized subproblems is a separable function of the Lagrange multipliers and thus, the update of each design variable is dependent only on the Lagrange multiplier of its associated volume constraint. By tailoring the ZPR design variable update scheme to the continuum setting, each volume constraint is updated independently. This formulation leads to a setting in which sufficiently general volume/mass constraints can be specified, i.e., each volume/mass constraint can control either all or a subset of the candidate materials and can control either the entire domain (global constraints) or a sub-region of the domain (local constraints). Material interpolation schemes are investigated and coupled with the presented approach. The key ideas presented herein are demonstrated through representative examples in 2D and 3D.

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During calendar year 2017, Sandia National Laboratories (SNL) made strides towards developing an open portable design platform rich in highperformance computing (HPC) enabled modeling, analysis and synthesis tools. The main focus was to lay the foundations of the core interfaces that will enable plug-n-play insertion of synthesis optimization technologies in the areas of modeling, analysis and synthesis.

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Additive manufacturing offers unprecedented opportunities to design complex structures optimized for performance envelopes inaccessible under conventional manufacturing constraints. Additive processes also promote realization of engineered materials with microstructures and properties that are impossible via traditional synthesis techniques. Enthused by these capabilities, optimization design tools have experienced a recent revival. The current capabilities of additive processes and optimization tools are summarized briefly, while an emerging opportunity is discussed to achieve a holistic design paradigm whereby computational tools are integrated with stochastic process and material awareness to enable the concurrent optimization of design topologies, material constructs and fabrication processes.

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