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Frontiers of Mechanical Engineering

ISSN 2095-0233

ISSN 2095-0241(Online)

CN 11-5984/TH

Postal Subscription Code 80-975

2018 Impact Factor: 0.989

Front. Mech. Eng.    2022, Vol. 17 Issue (2) : 27    https://doi.org/10.1007/s11465-022-0683-5
RESEARCH ARTICLE
Robust isogeometric topology optimization for piezoelectric actuators with uniform manufacturability
Jie GAO1,2, Mi XIAO3, Zhi YAN1,2(), Liang GAO3(), Hao LI3
1. Department of Engineering Mechanics, School of Aerospace Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
2. Hubei Key Laboratory for Engineering Structural Analysis and Safety Assessment, Huazhong University of Science and Technology, Wuhan 430074, China
3. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China
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Abstract

Piezoelectric actuators have received substantial attention among the industry and academia due to quick responses, such as high output force, high stiffness, high accuracy, and precision. However, the design of piezoelectric actuators always suffers from the emergence of several localized hinges with only one-node connection, which have difficulty satisfying manufacturing and machining requirements (from the over- or under-etching devices). The main purpose of the current paper is to propose a robust isogeometric topology optimization (RITO) method for the design of piezoelectric actuators, which can effectively remove the critical issue induced by one-node connected hinges and simultaneously maintain uniform manufacturability in the optimized topologies. In RITO, the isogeometric analysis replacing the conventional finite element method is applied to compute the unknown electro elastic fields in piezoelectric materials, which can improve numerical accuracy and then enhance iterative stability. The erode–dilate operator is introduced in topology representation to construct the eroded, intermediate, and dilated density distribution functions by non-uniform rational B-splines. Finally, the RITO formulation for the design of piezoelectric materials is developed, and several numerical examples are performed to test the effectiveness and efficiency of the proposed RITO method.

Keywords piezoelectric actuator      isogeometric topology optimization      uniform manufacturability      robust formulation      density distribution function     
Corresponding Author(s): Zhi YAN,Liang GAO   
About author:

Tongcan Cui and Yizhe Hou contributed equally to this work.

Just Accepted Date: 22 April 2022   Issue Date: 15 August 2022
 Cite this article:   
Jie GAO,Mi XIAO,Zhi YAN, et al. Robust isogeometric topology optimization for piezoelectric actuators with uniform manufacturability[J]. Front. Mech. Eng., 2022, 17(2): 27.
 URL:  
https://academic.hep.com.cn/fme/EN/10.1007/s11465-022-0683-5
https://academic.hep.com.cn/fme/EN/Y2022/V17/I2/27
Fig.1  Several designs with one-node connected hinges: (a) an optimized design of an inverter; (b) structural deformation of optimized design (a); (c) blue-print design of an inverter with uniform manufacturability; (d) structural deformation of optimized design (c). (a), (b), (c), and (d) are reprinted with permission from Ref. [49] from Springer Nature. (e) A design of piezoelectric actuator, reprinted with permission from Ref. [22] from Springer Nature; (f) a design of piezoelectric actuator, reprinted with permission from Ref. [18] from IOP Publishing; (g) a design of piezoelectric actuator, reprinted with permission from Ref. [20] from Elsevier.
Fig.2  Definition of DDF and its corresponding topology. (a) Step 1: control design variables; (b) Step 2: smoothing mechanism; (c) Step 3: threshold projection; (d) Step 4: DDF; (e) Step 5: topology. DDF: density distribution function.
Fig.3  Erode–dilate operator for DDF. DDF: density distribution function.
Domain L H NURBS orders Control points IGA elements Vmax
1 10?2 10?2 [3, 3] 102 × 102 100 × 100 0.26
2 10?2 10?2 [3, 3] 102 × 102 100 × 100 0.20
3 10?2 10?2 [3, 3] 102 × 102 100 × 100 0.30
Tab.1  Related parameters in the three structural design domains
Fig.4  Boundary and load conditions of (a) structural design domain 1, (b) structural design domain 2, and (c) structural design domain 3.
Fig.5  Color setting in DDF, topology, and polarization.
Fig.6  Optimized designs of the first domain for three different cases: optimized DDF of structural design domain 1 with stiffness equal to (a1) 0.01, (a2) 0.005, and (a3) 0.0015; optimized topology of structural design domain 1 with stiffness equal to (b1) 0.01, (b2) 0.005, and (b3) 0.0015; (c1), (c2), and (c3) layout of polarization in optimized topology in (b1), (b2), and (b3), respectively.
Fig.7  Iterative histories of objective function and volume fraction in optimization of Fig. 6(b3).
Case kuu1, kuu2, kuu3, and kuu4 in Fig.4(b) kuu in Fig.4(c) uout/10?7
In Fig.4(b) In Fig.4(c)
Case 1 0.010 0.010 4.54 14.8
Case 2 0.005 0.005 5.57 19.6
Case 3 0.001 0.002 23.00 31.4
Tab.2  Spring stiffness and optimized displacement of piezoelectric actuator in Figs. 4(b) and 4(c)
Fig.8  Optimized designs of the second design domain for three different cases: (a1) optimized topology of structural design domain 2 with stiffness equal to 0.01, (a2) layout of polarization in optimized topology in (a1), (b1) optimized DDF of structural design domain 2 with stiffness equal to 0.005, (b2) layout of polarization in optimized topology in (b1), (c1) optimized DDF of structural design domain 2 with stiffness equal to 0.001, and (c2) layout of polarization in optimized topology in (c1).
Fig.9  Optimized designs of the third design domain for three different cases: (a1) optimized topology of structural design domain 3 with stiffness equal to 0.01, (a2) layout of polarization in optimized topology in (a1), (b1) optimized DDF of structural design domain 3 with stiffness equal to 0.005, (b2) layout of polarization in optimized topology in (b1), (c1) optimized DDF of structural design domain 3 with stiffness equal to 0.002, and (c2) layout of polarization in optimized topology in (c1).
Design Output displacement/10?6 Volume fraction
Eroded design 2.38 0.22
Intermediate design 3.23 0.26
Dilated design 1.68 0.30
Tab.3  Output displacement and volume fraction of the three designs
Fig.10  Robust designs of the first domain using RITO formulation: optimized DDF of (a1) eroded design, (a2) intermediate design, and (a3) dilated design; optimized topology of (b1) eroded design, (b2) intermediate design, and (b3) dilated design; (c1), (c2), and (c3) corresponding layout of polarization in optimized topology in (b1), (b2), and (b3), respectively.
Fig.11  Convergent histories of objective function and volume fraction in RITO optimization for the first design domain.
Fig.12  Robust designs of the second domain using RITO formulation: (a1) optimized topology of eroded design, (a2) corresponding layout of polarization in optimized topology in (a1), (b1) optimized topology of intermediate design, (b2) corresponding layout of polarization in optimized topology in (b1), (c1) optimized topology of dilated design, and (c2) corresponding layout of polarization in optimized topology in (c1).
Fig.13  Robust designs of the third domain using RITO formulation: (a1) optimized topology of eroded design, (a2) corresponding layout of polarization in optimized topology in (a1), (b1) optimized topology of intermediate design, (b2) corresponding layout of polarization in optimized topology in (b1), (c1) optimized topology of dilated design, and (c2) corresponding layout of polarization in optimized topology in (c1).
Design Output displacement/10?6 Volume fraction
In Fig.12 In Fig.13 In Fig.12 In Fig.13
Eroded design 1.72 3.30 0.15 0.25
Intermediate design 1.99 3.74 0.20 0.30
Dilated design 1.35 2.75 0.25 0.35
Tab.4  Numerical results containing the output displacement and final volume fraction of Figs. 12 and 13
Design domain Deterministic design/10?6 Blue-print design/10?6
First domain 3.51 3.23
Second domain 2.30 1.99
Third domain 3.14 3.74
Tab.5  Comparison of output displacements between deterministic designs and robustly blue-print designs for three domains
Fig.14  Comparison between deterministic design by ITO and robustly blue-print design by RITO for the three domains: (a1) deterministic design of the first design domain, (a2) blue-print design of the first design domain, (b1) deterministic design of the second design domain, (b2) blue-print design of the second design domain, (c1) deterministic design of the third design domain, and (c2) blue-print design of the third design domain.
Setting Parameters of threshold projection
Setting 1 ηeo=0.80,ηid=0.5,ηdo=0.20
Setting 2 ηeo=0.75,ηid=0.5,ηdo=0.25
Setting 3 ηeo=0.70,ηid=0.5,ηdo=0.30
Tab.6  Three different settings of parameter of threshold projection
Fig.15  Blue-print designs of the three design domains under three different settings: blue-print design of design domain 1 under (a1) setting 1, (a2) setting 2, and (a3) setting 3; blue-print design of design domain 2 under (b1) setting 1, (b2) setting 2, and (b3) setting 3; blue-print design of design domain 3 under (c1) setting 1, (c2) setting 2, and (c3) setting 3.
Abbreviations
CAMD Continuous approximation of material distribution
DDF Density distribution function
FEM Finite element method
IGA Isogeometric analysis
ITO Isogeometric topology optimization
MEMS Micro-electro-mechanical system
MMA Method of moving asymptotes
NURBS Non-uniform rational B-splines
OC Optimality criteria
PEMAP Piezoelectric material with penalization
PEMAP-P Piezoelectric material with penalization and polarization
PZT Lead zirconate titanate
RITO Robust isogeometric topology optimization
SIMP Solid isotropic material penalization
Variables
Bu Strain?displacement matrix
cE Stiffness tensor in constant electrical field
D Electrical displacement
e Number of the finite element
e Piezoelectric coefficient matrix
E Electrical field
E0,e0,ε0 Stiffness, electromechanical coupling, and dielectric coefficients of piezoelectric solids, respectively
Emin, emin, εmin Minimum values of stiffness, electromechanical coup-ling, and dielectric coefficients of the voids, respectively
f Global force imposed at the design domain
fb Body force
fd Dummy load
fe Force in the eth finite element
fs Surface traction
G1 Volume constraint for the eroded, intermediate, and dilated topologies
G2 Volume constraint in the intermediate design
G(Φ) Volume constraint function
h Thickness of the piezoelectric plate
i Number of control point in the first parametric direction
j Number of control point in the second parametric direction
J Objective function
J1 Jacobi matrix from the parametric space to physical space
J2 Jacobi matrix from the bi-unit parent element space to parametric space
kuu Spring stiffness at the output location
kuu Mechanical stiffness matrix
ku? Piezoelectric coupling matrix
k?? Dielectric stiffness matrix
m, n Total number of control points in the parametric directions η and ξ, respectively
Mj,q B-spline basis functions in the second parametric direction
Ni,p B-spline basis functions in the first parametric direction
p Degree of NURBS basis functions in the first parametric direction
puu, pu?, p??, ppo Penalization parameters for stiffness, piezoelectricity, dielectric, and polarization, respectively
q Degree of NURBS basis functions in the second parametric direction
qc Surface charge density accumulated on the electrodes
qe Charge density in the eth finite element
Ri,jp,q NURBS basis functions in 2D
S Mechanical strain
T Mechanical stress
u Displacement field
ue Displacement field in the eth finite element
ui,j Displacement at the (i,j)th control point
uout Output displacement at the specified locations of the design domain
Vmax Maximum material consumption
ωi,j Positive weight at the (i,j)th control point
ξ,ζ First and second parametric directions, respectively
εS Permittivity coefficient matrix
? Electric potential
?e Electric potential in the eth finite element
Ωe Physical design domain of the eth IGA element
Ω~ Bi-unit parent element
φ Control design variable
φmin Positive integer to avoid the occurrence of numerical singularity
φ^eo,φ^id, φ^do Eroded, intermediate, and dilated control design variables, respectively
φ~i,j (i,j)th smoothed control design variable
β, η First and second parameters in the threshold projection, respectively
ηeo,ηid,ηdo Different values of the parameter η to define the erode, intermediate and dilate operators in threshold projection, respectively
λ Adjoint vector of the dummy load
Φ Density distribution function
Φeo,Φid, Φdo Eroded, intermediate, and dilated DDFs, respectively
Φiso Value of the iso-contour of the DDF
Φtop Structural topology
Φtopeo,Φtopid, Φtopdo Eroded, intermediate, and dilated topologies, respectively
ψ Second type of design variables for the polarization
Ψ Continuous function for the second type of design variable
Ψeo,Ψid,Ψdo Eroded, intermediate, and dilated continuous functions for the second type of design variable, respectively
Ψtopeo,Ψtopid, Ψtopdo Optimized distributions of the polarization in three eroded, intermediate, and dilated designs, respectively
  
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