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Structu Optimization
0 Springer-Verla 8 1992
V.B. V e n k a y y a
Flight Dynamics Directorate, Wright Patterson Air Force Base, Ohio, USA
Abstract The objective of this work is to demonstrate the structural optimization problem in order to derive the neces-
generalized compound scaling algorithm in the design of plate sary conditions for an extremum.
structures with frequency constraints. The robustness of the algo- The optimal design of structures with a natural frequency
rithm is demonstrated on large scale problems using scaling tech-
constraint was developed by Haug et al. (1972) for a simply
nique alone. This paper presents the optimization algorithm, nu-
merical results and discussions. Design histories and the first few supported, square plate using the generalized steepest de-
frequencies at the initial and optimum condition are also included. scent method. The problem was solved using a collocation
technique wherein only a finite number of structural elements
were used and sensitivities were evaluated by using finite dif-
ference techniques. The same authors (1975) optimized a
1 Introduction simply supported square plate using a continuous formulation
Plate elements play an important role in built-up structures approach. In the continuum problem, equations governing
used in aerospace, automotive and civil engineering appli- stress, displacement and vibration consisted of a boundary
cations. Dynamic characteristics of these structures can be value problem of ordinary differential equations and ellip-
improved by placing the natural frequencies of the system tic partial differential equations. A steepest descent method
in selected ranges. The objective of this research work is to for the boundary-value state equations was developed. The
optimize !arge scale plate structures with multiple frequency authors concluded that the continuous optimal design ap-
constraints. A large number of publications on structural proach was not directly applicable to large-scale structures
optimization with frequency constraints is available. A very with many numbers. It does, however, have features that
limited number of researchers has considered plate bending make it attractive for the design of special purpose elements
problems due to the complexity of the element formulation, or for the solution of an initial model of a large-scale struc-
computational requirements, and non-uniqueness of optimum tures, prior to fine discretization for a detailed design.
solutions. Kamat (1973) optimized thin rectangular plates for op-
In this paper, the optimum design of plate structures timum fundamental frequency using the finite element ap-
with multiple frequency constraints is considered. Haftka proach. The results obtained suggested the non-uniqueness
and Prasad (1981) surveyed the previous work done on struc- of solutions, and provided an explanation of the difficulty in
tural optimization of plate bending elements. The authors determining a true global optimum. Foley (1978) optimized
observed that the design of plates subject to frequency con- a simply supported, square plate for minimum weight with a
straints can be specifically tailored to the problem at hand. fixed fundamental frequency of free vibration. The plate was
This can be achieved by using variational principles or can be optimized using the e method. The basic idea of this method
formulated using general mathematical programming tech- was to replace the differential equation modeling the system
niques and finite element analysis. Selected publications of with a penalty function, thus transforming the original dy-
the previous work on frequency optimization are discussed namic problem into a nondynamic one. Most of the work de-
below. scribed above was done using the optimal control approach
Historically, the first investigations (DeSilva 1972; Olhoff or the continuous distribution approach. Recently, Leal and
1974; Seiranyan 1978) were concerned with the optimal de- Mota Soares (1989) optimized plates subject to static, dy-
sign of a circular plate with a constraint on the fundamental namic and stability constraints using mixed finite elements.
frequency of vibration and assumed the corresponding mode The authors used the ADS (Automated Design Synthesis)
to be symmetric. Armand (1971) addressed the problem of a program for optimization and discussed the advantages and
shear plate that had no bending rigidity for normal loads, and disadvantages of mixed elements in design optimization of
analytically obtained the minimum weight design of a simply plates.
supported, rectangular shear plate with a prescribed funda- Recent work done by Grandhi el al. (1991) studied the
mental frequency of free vibration. He extended the classi- optimum design of plate structures with stress and displace-
cal methods of optimal control theory to a two-dimensional ment constraints using the generalized compound scaling al-
i01
gorithm. As an extension to the work done by the above linked to the spurious modes. This procedure is implemented
authors, multiple frequency optimization, using the general- by formulating the mass matrix for the bilinear Mindlin plate
ized compound scaling algorithm for reaching the optimum, is element using a one-point integration for the inplane motions,
presented in this paper. Multiple frequencies were considered and the projection method for the transverse displacements
with and without non-structural masses on the structure. De- and rotations using 2 × 2 quadrature. This projection method
tails of the finite element formulation, optimization algorithm suppresses hourglassing kinetic energies, but allows a correct
and numerical results are presented. The computational ef- evaluation of the kinetic energy for all constant strain and
fort involved in the optimzation part of these problems was rigid body motions by using a modified kinetic energy based
minimal. on the purely linear part of the velocity field. The algorithm
used in this work is taken from Brockman et al. (1989). It
should be noted that the mass matrix, M, includes the effect
2 F E M f o r m u l a t i o n a n d sensitivity analysis of non-structural mass distribution.
A four-noded, bilinear displacement element based on the Eigenvalue sensitivities with respect to the thickness of
Mindlin theory of plates was used for modeling the struc- an element are computed using the following equation:
tures. Such elements exhibit good accuracy for plates when KUj - w2 MUj = O, (8)
reduced numerical integration is used to evaluate the element
where w2 is the eigenvalue of the j-th mode of the structure,
matrices. However, the resulting matrices are rank-deficient,
since bilinear contributions to the displacement field are not and Uj is the corresponding eigenvector. Differentiating (8)
with respect to the design variable, the thickness parameter
captured by the single-point integration. This results in spu-
rious singular modes which need to be controlled to achieve leads to the frequency sensitivity expression as follows for the
reliable element behaviour. A low order quadrature is desir- j-th mode of vibration:
able for two reasons. First, since the expense of generating a Nel
stiffness matrix K or mass matrix M by numerical integra-
wj - - 2wjmj e=l
tion is proportional to the number of sampling points, fewer
sampling points mean lower cost. Second, a low order rule The denominator is a scalar multiple of the generalized
tends to soften an element, thus countering the overly stiff be- mass for mode j, which is given by mj = UT MUj. The
haviour associated with an assumed displacement field. Soft- product K I U is simple to calculate when the sensitivity pa-
ening comes as certain higher-order polynomial terms vanish rameter is the thickness, since only the elasticity matrix is
at the Gaussian integration points of a low-order rule, so that affected. Hence -~ = D I BU and
these terms make no contribution to the strain energy.
K' U = [ BTNJI d r , (10)
The element considered here has twenty degrees of free-
dom, three translation and two rotational motions per node. V
The stiffnesss matrix consists of three components: mem- where B is the strain displacement matrix, D is the elastic-
brane, bending and shear. The membrane and shear com- ity matrix, J is the Jacobian, and V is the volume of the
ponents of the stiffness matrix vary linearly with the plate element. The product in (10) is analogous to the usual pro-
thickness, while the bending component has a cubic relation cess of stress recovery, so that the calculation of K I U for the
with thickness. Belytschko and Tsay (1983) developed a sta- element resembles an evaluation of the internal nodal forces;
bilization procedure for controlling the kinematic modes of M t U is evaluated using the information
the four-noded bilinear element when single-point quadra- M =/RNNTIj[ dV, (11)
ture is used. In order to control the kinematic modes, the
authors defined generalized strains which are activated by V
these modes, but vanish in rigid body motions. Also associ- where R (rotary inertia coupling) is a function of the element
ated with these generalized strains are generalized stiffnesses density and thickness, and N is the shape functions matrix.
determined through numerical experiments. By using a scal- Thus for the mass matrix sensitivity, when the design variable
ing law, the stabilization parameters were defined so that is the thickness, only the parameter R is differentiated at the
they would not adversely affect the element's performance. element level.
The stabilization scheme outlined by the above authors is
effective for static problems in which the anti-hourglass stiff- 2.1 Optimization problem
ness may be adjusted freely to produce stable element be- The problem of minimizing the weight of a structure subject
haviour. In dynamics, however, low-energy deformation pat- to multiple constraints can be posed as
terns, consisting mainly of hourglass motions, represent likely minimize W = W(Xl, x 2 , . . . , z n ) , (12)
modes of low frequency oscillation which result in anomalous subject to the constraints
behaviour in some relatively low-frequency modes, and may
be traced directly to the effect of the stabilization opera- gj(x 1, x 2 , . . . , X n ) < ~ j j=l, 2,...,p, (13a)
tor. This difficulty was corrected by Brockman (1987) by us- gj(xl, x 2 , . . . , X n ) = ~ j j=p+ l,..., m, (135)
ing appropriate mass characteristics for the bilinear Mindlin and the side bounds on the design variable as
plate element with hourglass stabilization. The purpose of
this formulation was to associate the proper kinetic energy xi>_x.!/) , i = 1 , 2 , . . . , n , (14)
with those motions for which the element correctly repre- where W is the weight of the structure, n is the number of
sents the strain energy, and to eliminate the kinetic energy design variables and m is the total number of constraints.
102
algorithm (GCS), the objective function is treated as an ad- AjN = (-~j) ~jN , PjN > , (20)
ditional constraint, as both the constraints and the objective
or
function are functions of the same variables (Venkayya 1991). 1
However, the difficulty in this is that the constraints have a Ajp = (flj)vJP , #jN < #jP" (21)
target to satisfy and the objective function does not. Hence The following conditions are used in constructing the scale
to make the objective function look like a constraint, pseudo factors matrix:
target values for the objective function are generated so that
it can be treated as an additional constraint which intersects
Aij = AjN Pij < 0 t
Aij = 1.0 Pij <- 0 , ttjN >- #JP' (22a)
other constraints. The details of the GCS algorithm are pre-
or
sented below.
Two parameters,/3 and p, play a key role in the general- Aij = ~jP Pij > 0 t
Aij = 1.0 #ij <- 0 ~ # j g < #jR. (225)
ized compound scaling. First fl parameters are computed for
all the constraints using the following expression: This formulation results in s + 1 possible scale factors for
each variable. The strategy in compound sealing is to select
flgj = gJ = target response ratio. (15) a mix of the scale factors from various columns of the scale
gj
factor table with the object of approaching the intersection
After arranging the constraints with/?'s in the ascending or- points of the constraints. The relevant scale factors are deter-
der, the constraints with the lowest/3 values being the most mined with the help of a scale factor assignment procedure.
critical are selected for the active constraints set (about 10 The scale factors assignment table is computed as follows:
to 15) and denoted by s.
t i j = Nijxi
zj + #jN Pij < 0 }
Next, the function characteristics parameter p is com-
puted for each of the selected s constraints and the objective tij = 0 Pij >--0 PiN >--PiP, (23a)
function. The tt parameter consists of two parts based on the or
//
L.
I-
10° _ ~
64
43 49
56
O 39
48
/k 40
OlD
25
32
24
16
Z
1 8
Iteration no.
Mesh 7 X 7
X ElementNo.
Fig. 2. Simply supported plate design iteration history X GridPointNumber
"-~-~ SupportPoint
was 0.02 in. The initial design started from a feasible point Fig. 3. Plate supported along four diagonal points
and had a weight of 12.34 lb when all the design variable
thicknesses were at 0.71 in. The structural weight was min- was active at the optimum. In both cases, elements near the
imized such that the fundamental and second frequencies support point and the lower left corner were thicker than
were constrained. Tables 1 and 2 present the results ob- the rest of the elements. As previously noted by Haftka ahd
tained under different constraint conditions. The first case Prasad (1981), optimum designs have discontinuous thickness
was with ~1 -> 4000"0~cd and the second case was with distributions.
tad Table 1 gives the first five
Wl >- 4000,0, Ws >_ 6000,0s-~.
frequencies at the initial and optimum designs. Figures 4a 4.3 Example 3: square plate with internal and edge supporls
and b give the mode shapes corresponding to the first and
second frequencies. As can be seen from Table 1, when the The third problem was a square plate with dimensions 12 in ×
12 in (Fig. 6). The plate is supported along its edges and also
plate is optimized for case 1 the second natural frequency
at internal locations to represent a platform structure with
comes very close to the first frequency and all the other freM
quencies are also much lower than the initial design values. several internal supports (total 88 simply supported nodes
For the second case the second and third frequencies come out of 169 nodes ). The plate can be considered to have been
closer to the optimum, but the fourth and fifth frequencies made up of nine blocks. The material properties are those
of aluminium, Young's modulus E = 107 psi, Poisson's ratio
move away to give a higher weight than the first case. Table
2 consists of all the design variables at the optimum. The u = 0 3 and mass density Pm = 2.587x 1vn-041bs2 in 4 • The plate
iteration history for the second case is shown in Fig. 5. For was modeled with 144 elements as a complete plate because of
that case it took 34 iterations to reach the optimal solution. the inherent properties of the plate. The first mode shape of
The first case took 27 iterations to reach the optimum. the plate has a quarter symmetry. The second and the third
In the first case, none of the elements reached the lower modes have diagonal skewed symmetry and the fourth mode
bound and the frequency constraint was active. In the second has a diagonal symmetry. Figures 7a and b give the mode
case, one element (number 25) near the point support of the shapes corresponding to the first and second natural frequen-
quarter plate went to the lower bound. The second constraint cies. A total of 24 lb of non-structural mass was added to
105
, ( ~ i ! .~ftt Ol
,4-
(a) Mode 1
t~
-~ -. 13
N.
T
o J ,
Iteration no.
(b) Mode 2 Fig. 5. Plate on four diagonal supports: design iteration history
Fig. 4. Plate on four diagonal supports: quarter model
the structure at all the free nodes. At the initial design, observed that structures with concentrated mass reached the
M1 the variables were taken as 1.0 in, which resulted in an optimum much faster than those without. The number of
inital weight of 38.4 lb. The plate was optimized for mini- design variables considered was considerably large. The al-
mum weight subjected to fundamental and second frequency gorithm proved to be extremely stable in giving'the optimum.
constraints. A minimum gauge value of 0.1 in was imposed The optimum thickness distributions realized in this work fol-
on all the design variables. Table 3 presents the results ob- low the trends discussed by previous researchers (Rozvany el
tained under the follwing two different conditions. The first al. 1982). In general, solving the complete optimization prob-
case was with w 1 _> 32000.0 tad
s~~ and the second one was with lem for finding the optimum solution involves finite element
Wl -> 32000.0, w2 _> 35000.0s-tad
~ . The initial design was the analysis of the structure, sensitivity calculation of objective
infeasible region. Table 3 gives the first three frequencies at and constraints with respect to design variables, construction
the initial and optimum designs. The iteration history for the of function approximations, move limits, calculation of search
second case is shown in Fig. 8 and the thickness distributions direction, and iterative optimization methods. One major
at the optimum is shown in Fig. 9. Quarter model symmetry point to be noted with the GCS algorithm was its minimal
was realized at the optimal design for the first case. For the computational effort involved in calculating the scale factors
second case both the eigenvalues were active at the optimum and the assignment table needed for resizing the structure.
and a skewed diagonal symmetry was realized. No elements This simplicity results in substantial savings in solving very
were at their lower bounds and the constraints were active in large scale problemswith hundreds of design variables.
both of the cases. In general, elements at the center of each
block were thicker than the others.
Acknowledgements
5 Conclusions
In this paper, the minmum weight design of structures with This research work was supported by the U.S. Air Force through
single and multiple frequency constraints were obtained us- the contract, F33615-88-C-3204. The authors acknowledge Dr.
ing the generalized compound scaling algorithm. Structures R.A. Brockman, University of Dayton Research Institute, for pro-
with and without concentrated mass were considered. It was viding the PROTEC computer program.
106
9 0.7597 1.0762
10 0.7597 1.3714
11 0.9177 1.6859
117
12 0.7818 0.8678
13 0.2985 0.0551
14 0.0772 0.0496
15 0.7597 0.9720 ~5
16 0.6319 1.2512
17 0.9177 1.0828
18 0.4819 0.9721
1 1213
19 1.0805 1.0469
20 0.4551 0.3449
21 0.2111 0.2881 Mesh 12 x 12 x Element Number
22 0.7029 0.8197 X Grid Point Number
23 0.0762 0.1701
24 0.7923 1.2935 ~-. ~ Support Point
25 0.4494 0.0200 Fig. 6. Square plate with internal and edge supports
26 0.7658 0.4125
27 0.4494 0.3391
28 0.3596 0.3391
29 0.4663 0.2181
30 0.5048 0.2106
31 0.3490 1.2450
32 0.5244 0.4150
33 0.3486 0.4658
34 0.4542 0.4047
35 0.4494 0.2805
36 0.3252 0.1640
37 0.3577 0.4648
38 0.3577 0.4864
39 0.3577 0.3502
40 0.0719 0.3481
41 0.3486 0.3481
42 0.3486 0.1306
43 0.1551 0.4062
44 0.1324 0.3575
45 0.1596 0.3575 Fig. 7a. Square plate with internal and edge supports - mode 1
46 0.1525 0.3481
47 0.1183 0.3481 Num. Mech. Eng. 19, 405-419
48 0.1525 0.1306 Brockman, R.A.; Lung F.Y.; Braisted, W.R. 1989: Probabilistic
49 0.1908 0.1306 finite element analysis of dynamic structural response. Wright
Weight 10.38 11.52 Patterson Air Force Base, Technical Report, A F W A L - T R - 8 8 - 2 1 4 9
DeSilva, B.M.E. 1972: Optimal vibrational modes of a disc. J.
References Sound and Vibration 21, 19-34
Armand, J.L. 1971: Minimum-mass design of plate-like structures Foley, M.H. 1978: A minimum mass square plate with fixed fun-
for specified fundamental frequency. A I A A J. 9, 1739-1745 damental frequency of free vibration. A I A A J. 16, 1001-1004
Belytschko, T.; Tsay, C.S. 1983: A stabilization procedure for Grandhi, R.V., Venugopal, N.S.; Venkayya, V.B. 1991: Optimality
quadrilateral plate element with one-point quadrature. Int. J. criteria method for minimum weight design plate structures. Proc.
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