Optimal shaping of lightweight structures

Designing structures for lightness is an intelligent and responsible way for engineers and architects to conceive structural systems. Lightweight structures are able to bridge wide spans with a least amount of material. However, the quest for lightness remains an utopia without the driving constraints that give sense to contemporary structural design.Previously proposed computational methods for designing lightweight structures focused either on finding an equilibrium shape, or are restricted to fairly small design applications. In this work, we aim to develop a general, robust, and easy-to-use method that can handle many design parameters efficiently. These considerations have led to truss layout optimization, whose goal is to find the best material distribution within a given design domain discretized by a grid of nodal points and connected by tentative bars. This general approach is well established for topology optimization where structural component sizes and system connectivity are simultaneously optimized. The range of applications covers limit analysis and identification of failure mechanisms in soils and masonries. However, to fully realize the potential of truss layout optimization for the design of lightweight structures, the consideration of geometrical variables is necessary. The resulting truss geometry and topology optimization problem raises several fundamental and computational challenges. Our strategy to address the problem combines mathematical programming and structural mechanics: the structural properties of the optimal solution are used for devising the novel formulation. To avoid singularities arising in optimal configurations, the present approach disaggregates the equilibrium equations and fully integrates their basic elements within the optimization formulation. The resulting tool incorporates elastic and plastic design, stress and displacements constraints, as well as self-weight and multiple loading.Besides, the inherent slenderness of lightweight structures requires the study of stability issues. As a remedy, we develop a conceptually simple but efficient method to include local and nodal stability constraints in the formulation. Several numerical examples illustrate the impact of stability considerations on the optimal design.Finally, the investigation on realistic design problems confirms the practical applicability of the proposed method. It is shown how we can generate a range of optimal designs by varying design settings. In that regard, the computational design method mostly requires the designer a good knowledge of structural design to provide the initial guess.Doctorat en Sciences de l'ingénieur