Topology Optimization of Multi-Component Structures

Topology optimization is an effective tool for the design of efficient engineering structures. The vast majority of existing topology optimization literature focusses on the optimization of single component structures. However, in real-world applications, engineering structures are rarely manufactured, transported and assembled as a single component. They are instead subdivided into constituent components which are typically manufactured separately and later assembled to form a larger structure. Furthermore, assembly of these structures relies upon some form of interfacing connections to fasten the components together, such as screws, welds, or rivets. These practical requirements are often critical factors within the design process but are unfortunately difficult to include within many existing topology optimization approaches. The lack of proven and accepted methods to merge real-world connectivity options with the algorithmic design of optimized structures has arguably inhibited the uptake of topology optimization in the wider engineering industry. This thesis aims to extend the scope of topology optimization procedures by incorporating some of these more realistic structural constraints within existing optimization methodologies. This is done with the intention of improving the availability of topology optimization approaches to the engineering practice and helping provide more effective design strategies for industrial applications. Specifically, this thesis reviews the current state of published literature with a broad overview of general topology optimization and a finer focus on existing multi-component topology optimization approaches. Knowledge gaps in existing literature are identified and are subsequently explored throughout this thesis via two distinct approaches. Firstly, through incorporation of interfacing connections between components in multi-component structures for which optimization methodologies are presented allowing simultaneous optimization of all structural components and their interfaces. Secondly, through further development of periodic optimization methodologies in which structures consisting of a finite number of identical components are optimized. Design criteria such as stiffness, stress, and natural frequency are considered throughout. Several numerical examples are presented within each chapter to demonstrate the efficacy of the proposed design approaches