<p>Lightweight structural design is crucial in aerospace engineering, as it reduces mass and enhances material efficiency, ultimately lowering costs. Key to this process is understanding material–structure interactions, which allow engineers to create high-performance components that exceed traditional design limits. Researchers have primarily focused on single-scale structures due to manufacturing limitations, but the rise of 3D printing now makes it feasible to create complex multiscale porous structures. This paper introduces an efficient concurrent topology optimization method for multi-substructure hierarchical structures using the Extended Multiscale Finite Element Method (EMsFEM) and concurrent Solid Isotropic Material with Penalization (SIMP) approaches. This approach addresses diverse multiscale optimization challenges, including single/multiple microstructures, compliance/ stress objectives, and composite/lattice materials. To facilitate practical application, this paper provides MATLAB code implementations for displacement and stress objectives. This study introduces a stress representation technique and a stress penalization mechanism for multiscale structures, marking the first application of EMsFEM to stress-focused optimization‌. This method calculates microscopic unit stresses while achieving equivalent stiffness, overcoming limitations imposed by length-scale separation. Numerical examples validate the correctness of the proposed approach, demonstrating its ability to ensure connectivity between distinct microstructures. Furthermore, this study analyzes multiscale optimization outcomes for composite and lattice materials under varying objectives. Based on numerical results, it investigates the mechanical mechanisms of distinct materials, providing practical tools and insights for material-structure integrated design.</p>

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An integrated SIMP-EMsFEM approach for concurrent multiscale optimization of compliance and stress in topology design

  • Jiaxi Li,
  • Weian Yao,
  • Yan Sun,
  • Jianqiang Chen

摘要

Lightweight structural design is crucial in aerospace engineering, as it reduces mass and enhances material efficiency, ultimately lowering costs. Key to this process is understanding material–structure interactions, which allow engineers to create high-performance components that exceed traditional design limits. Researchers have primarily focused on single-scale structures due to manufacturing limitations, but the rise of 3D printing now makes it feasible to create complex multiscale porous structures. This paper introduces an efficient concurrent topology optimization method for multi-substructure hierarchical structures using the Extended Multiscale Finite Element Method (EMsFEM) and concurrent Solid Isotropic Material with Penalization (SIMP) approaches. This approach addresses diverse multiscale optimization challenges, including single/multiple microstructures, compliance/ stress objectives, and composite/lattice materials. To facilitate practical application, this paper provides MATLAB code implementations for displacement and stress objectives. This study introduces a stress representation technique and a stress penalization mechanism for multiscale structures, marking the first application of EMsFEM to stress-focused optimization‌. This method calculates microscopic unit stresses while achieving equivalent stiffness, overcoming limitations imposed by length-scale separation. Numerical examples validate the correctness of the proposed approach, demonstrating its ability to ensure connectivity between distinct microstructures. Furthermore, this study analyzes multiscale optimization outcomes for composite and lattice materials under varying objectives. Based on numerical results, it investigates the mechanical mechanisms of distinct materials, providing practical tools and insights for material-structure integrated design.