Concurrent optimization of topological configuration and continuous fiber path for composite structures — A unified level set approach

• Published in: Computer methods in applied mechanics and engineering Vol. 399; p. 115350
• Main Authors: Xu, Yanan, Gao, Yunkai, Wu, Chi, Fang, Jianguang, Sun, Guangyong, Steven, Grant P., Li, Qing
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 01.09.2022; Elsevier BV
• Subjects: Carbon fiber reinforced plastic (CFRP) composites; Composite structures; Continuous fiber composites; Design optimization; Fiber orientation; Fiber path optimization; Isotropic material; Level set method; Manufacturing constraints; Optimization; Radial basis function; Steering; Topology optimization; Topology optimization; Manufacturing constraints; Level set method; Fiber path optimization; Carbon fiber reinforced plastic (CFRP) composites
• ISSN: 0045-7825; 1879-2138
• DOI: 10.1016/j.cma.2022.115350

This study proposes a novel topology optimization approach for design of continuous steering fiber path for composite structures using a level set method. The radial basis function (RBF) is employed to construct the level set function (LSF). Fiber orientations are parameterized by LSF and fiber paths can be determined instinctively for the inherent advantages of the level set approach. Besides, the fast-marching method is employed to extrapolate the primary fiber paths to the secondary fiber paths, which can avoid the manufacturing drawbacks such as gaps and overlaps to a large extent. A detection and filtering technique is proposed here to alleviate the orientation disorder at the intersection of the diffusion surfaces. Two design schemes are developed to optimize both structural topology and fiber path. In a sequential procedure, topology optimization is conducted first with isotropic materials; and then fiber paths are optimized on the basis of fixed topological boundary. In a simultaneous optimization procedure, structural boundaries and fiber paths are optimized alternately through two inner loops. In this study, three numerical examples are presented to demonstrate the effectiveness of the proposed methods, and the results show that optimization of fiber path is beneficial to improvement of structural performance. In general, the simultaneous optimization scheme exhibits better optimal outcome in comparison with the sequential optimization scheme.