• Steel and Composite Structures
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• v.48 no.1
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• pp.73-88
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• 2023

This paper presents a novel implicit level set method for topology optimization of functionally graded (FG) structures with pre-existing discontinuities (pre-cracks) using radial basis functions (RBF). The mathematical formulation of the optimization problem is developed by incorporating RBF-based nodal densities as design variables and minimizing compliance as the objective function. To accurately capture crack-tip behavior, crack-tip enrichment functions are introduced, and an eXtended Finite Element Method (X-FEM) is employed for analyzing the mechanical response of FG structures with strong discontinuities. The enforcement of boundary conditions is achieved using the Hamilton-Jacobi method. The study provides detailed mathematical expressions for topology optimization of systems with defects using FG materials. Numerical examples are presented to demonstrate the efficiency and reliability of the proposed methodology.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.23 no.1
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• pp.84-91
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• 2013

Ultrasonic flip-chip bonding needs a precise bonding tool which delivers ultrasonic energy into chip bumps effectively to use the selected resonance mode and frequency of the horn structure. The bonding tool is excited at the resonance frequency and the input and output ports should locate at the anti-nodal points of the resonance mode. In this study, we propose new design method with topology optimization for ultrasonic bonding tools. The SIMP(solid isotropic material with penalization) method is used to formulate topology optimization and OC(optimal criteria) algorithm is adopted for the update scheme. MAC(modal assurance criterion) tracking is used for the target frequency and mode. We fabricate two prototypes of ultrasonic tools which are based on 3D optimization models after reviewing 2D and 3D topology optimization results. The prototypes are satisfied with the ultrasonic frequency and vibration amplitude as the ultrasonic bonding tools.

• Journal of Welding and Joining
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• v.30 no.6
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• pp.113-119
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• 2012

Ultrasonic bonding is the novel packaging method for flip-chip with high yield and low-temperature bonding. The bonding module is a core part of the bonding machine, which can transfer the ultrasonic energy into the bonding spot. In this paper, we propose topology optimization technique which can make new design of boding modules due to the constraints on resonance frequency and mode shapes. The designed bonding module using topology optimization was fabricated in order to evaluate the bonding performance and reliable operation during the continuous bonding process. The actual production models based on the proposed design satisfied the target frequency range and ultrasonic power. The bonding test was performed using flip-chip with lead-free Sn-based bumps, the results confirmed that the bonding strength was sufficient with the designed bonding modules. Also the performance degradation of the bonding module was not observed after the 300-hour continuous process with bonding conditions.

• Steel and Composite Structures
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• v.35 no.1
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• pp.129-145
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• 2020

In typical, structural topology optimization plays a significant role to both increase stiffness and save mass of structures in the resulting design. This study contributes to a new numerical approach of topologically optimal design of Mindlin-Reissner plates considering Winkler foundation and mathematical formulations of multi-directional variable thickness of the plate by using multi-materials. While achieving optimal multi-material topologies of the plate with multi-directional variable thickness, the weight information of structures in terms of effective utilization of the material at the appropriate thickness location may be provided for engineers and designers of structures. Besides, numerical techniques of the well-established mixed interpolation of tensorial components 4 element (MITC4) is utilized to overcome a well-known shear locking problem occurring to thin plate models. The well-founded mathematical formulation of topology optimization problem with variable thickness Mindlin-Reissner plate structures by using multiple materials is derived in detail as one of main achievements of this article. Numerical examples verify that variable thickness Mindlin-Reissner plates on Winkler foundation have a significant effect on topologically optimal multi-material design results.

• Journal of the Computational Structural Engineering Institute of Korea
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• v.35 no.6
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• pp.367-374
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• 2022

This papter presents the use of the automatic differential method based on the backpropagation method to obtain the design sensitivity and its application to topology optimization considering the stress constraints. Solving topology optimization problems with stress constraints is difficult owing to singularities, the local nature of stress constraints, and nonlinearity with respect to design variables. To solve the singularity problem, the stress relaxation technique is used, and p-norm for stress constraints is applied instead of local stresses for global stress measures. To overcome the nonlinearity of the design variables in stress constraint problems, it is important to analytically obtain the exact design sensitivity. In conventional topology optimization, design sensitivity is obtained efficiently and accurately using the adjoint variable method; however, obtaining the design sensitivity analytically and additionally solving the adjoint equation is difficult. To address this problem, the design sensitivity is obtained using a backpropagation technique that is used to determine optimal weights and biases in the artificial neural network, and it is applied to the topology optimization with the stress constraints. The backpropagation technique is used in automatic differentiation and can simplify the calculation of the design sensitivity for the objectives or constraint functions without complicated analytical derivations. In addition, the backpropagation process is more computationally efficient than solving adjoint equations in sensitivity calculations.

• Journal of the Computational Structural Engineering Institute of Korea
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• v.35 no.2
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• pp.65-71
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• 2022

Recently, multi-material structural topology optimization is more critical because it provides reasonable solution to weight reduction challenges and can as well provide effective conceptual design. For conventional multi-material topology optimization (MMTO), the number of design variable increases when the number of candidate materials increases, and accordingly, a significant increase in computational time occurs. Therefore, MMTO with a single design variable, such as the phase section method (PSM) was proposed. This research is focused on improving the PSM, considering three major limitations: the composition ratio does not represent the area or volume ratio, design variables are not sufficiently concentrated to target values, and certain materials are created less than they are required. To address such limitations, the redefined composition ratio and adjusted parameters for better convergence are proposed. The validation of proposed modifications is verified via two- and three-dimensional numerical examples.

• Steel and Composite Structures
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• v.46 no.1
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• pp.33-51
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• 2023

This research presents a multi-material topology optimization for functionally graded material (FGM) and nonFGM with elastic buckling criteria. The elastic buckling based multi-material topology optimization of functionally graded steels (FGSs) uses a Jacobi scheme and a Method of Moving Asymptotes (MMA) as an expansion to revise the design variables shown first. Moreover, mathematical expressions for modified interpolation materials in the buckling framework are also described in detail. A Solid Isotropic Material with Penalization (SIMP) as well as a modified penalizing material model is utilized. Based on this investigation on the buckling constraint with homogenization material properties, this method for determining optimal shape is presented under buckling constraint parameters with non-homogenization material properties. For optimal problems, minimizing structural compliance like as an objective function is related to a given material volume and a buckling load factor. In this study, conflicts between structural stiffness and stability which cause an unfavorable effect on the performance of existing optimization procedures are reduced. A few structural design features illustrate the effectiveness and adjustability of an approach and provide some ideas for further expansions.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.11
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• pp.137-145
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• 2002

Electric vehicle body has to be subjected to uniform load and requires auxiliary equipment such as air pipe and electric wire pipe. Especially, the cross beam supports the weight of passenger and electrical equipments. a lightweight vehicle body is salutary to save operating costs and fuel consumption. Therefore this study is to perform the size and the shape optimization of crossbeam for electric vehicle using the method of topology optimization to introduce the concept of homogenization based on optimality criteria method which is efficient for the problem having the number of design variables and a few boundary condition. this provides the method to determine the optimum position and shape of circular hole in the cross beam and then can achieve the optimal design to reduce weight.

• Nuclear Engineering and Technology
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• v.53 no.7
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• pp.2268-2276
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• 2021

Spent nuclear fuel, which can degrade during long-term storage, must be transported intact in normal transport conditions. In this regard, many studies, including those involving Multi-Modal Transportation Test (MMTT) campaigns, have been conducted. In order to transport the spent fuel safely, a tie-down structure for supporting and transporting a cask containing the spent fuel is essential. To ensure its structural integrity, a method for finding an optimum conceptual design for the tie-down structure is presented. An optimized transportation test model of a tie-down structure for the KORAD-21 metal cask is derived based on the proposed optimization approach, and the transportation test model is manufactured by redesigning the optimized model to enable its producibility. The topology optimization approach presented in this paper can be used to obtain optimum conceptual designs of tie-down structures developed in the future.

• Proceedings of the Computational Structural Engineering Institute Conference
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• 2004.10a
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• pp.347-354
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• 2004

Using an efficient adjoint variable method, we develop a unified design sensitivity analysis (DSA) method considering both steady state nonlinear heat conduction and geometrical nonlinear elasticity problems. Design sensitivity expressions with respect to thermal conductivity and Young's modulus are derived. Beside the temperature and displacement adjoint equations, another coupled one is defined regarding the obtained adjoint displacement field as the adjoint load in temperature field. The developed DSA method is shown to be very efficient and further extended to a topology design optimization method for the nonlinear weakly coupled thermo-elasticity problems using a density approach.