Structural Optimization of Solid Components with

Topology Optimizing Structural Language

TopoSLang
Dirk Roos, Johannes Will
CAD-FEM GmbH, Grafing, Germany
Frank Vogel
inuTech GmbH, Seukendorf, Germany

Summary
In the design process the basic structural layout can be found using the structural optimization, such
as topology and shape optimization. During the last years numerous methods and software packages
have been developed. However, since these tools are commonly only able to determine the rough
form of the body, the results of topology optimization have to be further processed and translated by
hand or by additional programs. Therefore, the objective of the development of the presented software
program TopoSLang (Topology optimizing Structural Language) is to introduce an easy to use
software program for continuous optimization process. The proposed optimization methods provide an
automatic link from topology and shape optimization up to the geometry description in the frame of
existing CAD software. TopoSLang supports sophisticated topological optimization, mesh smoothing,
shape optimization in respect to stress relaxation and the automatic generation of STL-geometry
description to transfer the optimization results back to CAD. The user-friendly preparation of
mathematical algorithms improves the efficiency and extends the applicability of the conventional
optimization procedures.

Keywords
Structural optimization, topology optimization, shape optimization, mesh smoothing, biological growth,
software development

19th CAD-FEM Users Meeting 2001

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0.

Introduction

The determination of the structural layout is the basic problem of the design process. The numerical
simulation based on the finite element method can be utilized in the process of computer-aided
design. An advanced technological aid for the designer and development engineer is the structural
optimization, which creates weight-optimized design. However the existing finite element and
optimization technologies still have limitations to be practically used in the design process. The main
problem is a user-friendly continuous workflow from topology optimization back to a CAD-model.
This is the motivation of the cooperation project Development of a user-friendly finite element
tool for design optimization of solid components (funded by the Arbeitsgemeinschaft industrieller
Forschung AIF project ProINNO). The involved parties are the CAD-FEM GmbH, the inuTech GmbH,
the Mathematical Institute of the University of Bayreuth and the Institute of Structural Mechanics of the
Bauhaus University Weimar. The objective of the project is to advance topology and shape
optimization strategies for their user-friendly use in the early design process. All software
developments will be included in the software architecture of SLang (Structural Language) and
combined with user-friendly graphical user interface. Result of the software development is a software
platform for topology optimization, called TopoSLang.

1.

Topology Optimization

In topology optimization the structural geometry is described by "0 - 1" material distribution in a given
design space. In finite element analysis the material distribution can be interpreted as the element
pseudo-density distribution. The goal of the topology optimization is to find the pseudo-density
distribution, which minimizes the strain energy (optimal compliance design) or respectively results in
an optimized stiffness (as shown in Fig. 1 and 2).
In [6] a mathematically method is developed to solve these kinds of ill-posed non-convex
material distribution optimization problems by combining three disciplines, the structural optimization,
the relaxation of non-convex functional and homogenization of micro-structured materials. The
material is replaced by an equivalent homogenous substitute. The microstructure is to be assumed a
square (cube) with a square (cube) hole built of isotropic material. By changing the hole size of the
microstructure, volume variations between zero and one are possible. In [2] the homogenization
method is used to obtain the material properties of the substitute. However, the energy approach by
[9] is employed in this development. This energy approach is based on the assumption that the strain
energy of the square (cube) micro cell and its filled substitute are identical for any state of local strain.
Thus we have to apply the standard local states of strain as prescribed boundary deformations, and to
compute the strain energy values for the micro cell domain by applying finite element analysis at this
microscopic level (see [9] for details).

Fig. 1: The given design space could be a plane structure subjected to a vertical load V.

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Fig. 2: The topology optimization gives the "0 - 1" material distribution interpreted as the element
pseudo-density distribution.
In order to optimize the compliance subjected to a volume constraint, an optimality criterion (OC)
approach can be used [10]. This iterative method is based on the necessary conditions of first order,
which can be derived by means of first variation of an augmented Lagrangian of the underlying
continuous compliance optimization problem. The handling of multiple loading and the algorithmic
code conversion is specified in [10, 8]. The developed OC approach is very fast and efficient - largescale optimization problems with more than 100.000 elements can be solved. A filter strategy
(member size control) is implemented which removes the checker boarding effect using finite
elements with linear shape functions and controls the solidity of the resulting structure. With this
member size control the objectionable influence of the mesh density to the results is strongly relaxed.
For some problems in topological optimization consideration of stress constraints would be very
helpful. Unfortunately, using OC only one constraint can be considered in the optimization problem. To
overcome this limitation we implemented a sequential convex programming (SCP) approach [12]. In
every optimization iteration with SCP, a local convex approximation is considered and solved. The
SCP approach is very flexible since theoretically any arbitrary topology optimization can be solved:
multiple constraints, e.g. element stress constraints, any kind of objective, e.g. frequency optimization.
Again a filter strategy (member size control) is implemented to avoid checker boarding and control
solidity, as shown in Fig. 3.

Fig. 3: Material distribution in case of linear element shape functions without filter and using filter
approach.
With sophisticated mathematical algorithms it is possible to use linear elements for large-scale
problems, to avoid objectionable mesh dependence, to control solidity and to consider stress
constraints.

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2.

Mesh smoothing

The resulting surfaces after successful topological optimization, as shown in Fig. 4 are normally rough
and has to be smoothed. In TopoSLang an automatic smoothing procedure is available. All points of
the outer surface will be moved on a local least square second order polynomial The polynomial
approximates points located in the near of the considered point. A user-defined radius selects the
points. The local least square second order polynomial is oriented on a least square plain with u,v,wcoordinates. In order to avoid any degeneration of the finite elements, the mesh in the near of the
viewed point will be modified using static condensation. Fig. 5 shows the smoothed finite element
mesh.

Fig. 5: The finite element mesh after mesh

smoothing.

Fig. 4: The finite element mesh after topology

optimization.

After smoothing the optimized structure and FE-mesh relaxation analysis to check stress states can
be performed.

3.

Shape optimization in respect to stress relaxation using biological growth

After smoothing there may be still stresses exceeding critical stress states. For relaxation of these
stress peaks we use biological growth algorithms.
The natural evaluation leads towards a uniform stress state. That implies that no part of a
structure is overstressed or under stressed. Living biological structures adaptively achieve a nearconstant or uniform stress state. This is important because cracks and fatigue usually occur in regions
of high stress. Fig. 6 and 7 show an example of a biological growth optimization problem with 17 %
stress reduction.

Fig. 6: The Von Mises stress distribution of the Fig. 7: The resulting structure and the Von Mises
initial structure.
stress distribution after the biological growth
optimization.

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Using volumetric swelling of regions with concentrated stress state, we obtain structures with
increased lifetime in case of frequent cyclic loadings. On the other hand, using volumetric shrinking of
low stress regions, no structural material is wasted. Mattheck [7] developed a biological growth
method by volumetrically swelling or shrinking of a structure according to its stress distribution. This
computational method can be easily realized using pseudo-thermal strains
Thus, two finite element analysis runs are required per optimization step. The first step is the
swelling/shrinking iteration step using the actual pseudo-thermal strains. For the swelling/shrinking
iteration step we can use a separate set of restraint conditions. The second iteration step is based on
the updated nodal coordinates with respect to the displacements of the swelling/shrinking analysis.

4.

Transfer of new geometry via STL-format

A very important part of a continuous topology optimization is the transfer of the new geometry
approximation back to the CAD-environment. After testing of commercially available Reverse
Engineering tools we did not found any procedure to extract higher order CAD surfaces like B-Spline
surfaces with an acceptable amount of user interaction. Because of that, we decided to extract the
smoothed surface approximation of the optimized structure as STL-format. This standard format can
easily be extracted fully automatically and imported to any CAD-program. The TopoSLang STLsurfaces create watertight bodies, which can be processed as volumes in CAD-programs (see Fig.21).

5.

Software architecture based on SLang the Structural Language

The software for structural optimization analysis should encompass state-of-the-art technology in both
the structural FE-analysis as well as optimization analysis parts. This does not necessarily imply that
one single program package must include everything. Because we wanted to have the possibility of
connecting arbitrary external FE-solvers, Preprocessors or CAD-programs we choose to develop an
optimization platform.
Additionally it seems useful to formulate software tasks in small, easy to control steps. It
should be possible to combine these steps into larger segments, which can be executed repeatedly.
Such a software solution can be achieved by implementing a problem-oriented module set in which
the individual modules pertain to optimization and structural analysis. A dedicated modular software
package for stochastic structural analysis and optimization (SLang) along this line has conceptually
been presented several years ago by [3] and substantiated subsequently by [4]. In a way, SLang can
be seen as a toolbox containing the basic software products for both optimization and finite element
analysis, which can interact smoothly and transparently. SLang integrates finite elements and
optimization at a level, which appears to be sufficient for a wide range of engineering problems. In
addition, the recent developments in SLang allow further enhancement regarding non-linear
optimization [13], interprocess communication and parallel processing, which can be used
advantageously for structural optimization analysis.
In order to meet the above-mentioned requirements regarding interaction between
optimization and finite element analysis, SLang [1] has been chosen as basic software architecture for
the development of the optimization platform TopoSLang.
The methods of topology optimization, biological growth and mesh smoothing are included in
the SLang software and a user-friendly GUI was developed. The resulting software sub-package of
SLang is called TopoSLang. TopoSLang also includes the SLang FE-solver. Because of that, after
preparing the problem (meshing, loading, constrains) optionally all analysis can be done in
TopoSLang or external solver can be used. Presently the ANSYS solver is connected.

6.

Interfacing with other finite element software packages

Some user may wish to use arbitrary efficient and fast finite element solvers. For that reason we
defined an application programming interface (API) and so far connected the ANSYS solver to
TopoSLang. Analytical gradient information is needed for the OC and SCPIP approach. We can
connect external solvers in two ways. In case of compute the element gradients in ANSYS we use
ANSYS user programmable features (UPF). To avoid programming of external solvers we can also
use the internal finite element structure of TopoSLang. In case of a complete reproduction of external
FE-models the element gradients can be calculated without any modifications of external solvers.
Then the interfacing is realized using data files, as shown in Fig. 8.

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ANSYS

Commands & ANSYS

Parametric Design Language

data files
Commands &
SLang Macro Programming

SLang
the Structural
Language

Fig. 8: Interfacing between TopoSLang and ANSYS using APDL/MACRO programming.

For import of the finite element model a standardized interface between ANSYS and TopoSLang using
ANSYS ASCII-db format (*.cdb) was developed. An example of FE transfer can be seen in Fig. 9.

Fig. 9: Finite element model exchange from ANSYS to TopoSLang.

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7.

Graphical User Interface

A system independent customer-friendly user interface has been developed to facilitate the use of the
optimization platform. In Tab. 1 the considered alternatives of GUI libraries are listed.

Library

NT

Unix

Linux

Mac

Windows API

GTK

Motif

Mac API

JavaSwing/3D

wxWindows

Qt

Tab. 1: GUI libraries

The highest possible system independence was our dominant criterion. To avoid parallel development
effort for different hardware platforms the use of Windows API, GTK, Motif and Mac API was ruled out.

Fig. 10: Qt based GUI.

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Java Swing in connection with Java3D, widely used in current software developments has been
tested, though its performance has been judged unsatisfactory for large-scale problems. With the GUI
library wxWindows during the GUI development-compiling errors occurred frequently. Thus we
decided to use Qt. Qt is a popular commercial GUI toolkit. Additionally, it supports client-server
programming via TCP/IP sockets. Thereby, a job distribution even in heterogeneous networks is
possible.
The Qt based GUI is currently developed to provide topology optimization, biological growth
and mesh smoothing. Fig. 10 shows a typical QT based GUI of the optimization platform. By this way,
the user will be continuously supported in optimizing solid components, so profound mathematical
knowledge is not necessary. The user focus on definition of the physical part of the optimization
problem, i.e. objectives and constrains definition. For the mathematical parameters of the optimization
proper default values are defined.
Highest priority in the interface design has the user-frienly support of the topology optimization
workflow. The user will be continuously supported in optimizing solid components, so profound
mathematical knowledge is not necessary. The user can focus on the definition of the physical part of
the optimization problem, i.e. weigth reduction or load case combination. For all mathematical
parameters of the optimization algorithms proper default values are defined.

8.

An illustrating example and workflow of the optimization process

8.1

Preparing the problem

TopoSLang assumes that the user meshes the 3D-geometry with solid or tetrahedral elements,
defines the physical properties (Youngs Modulus, weight, Poissons ratio), the loading (different load
cases) and the constraints in an external preprocessor or CAD-program. At the moment we support
the ANSYS preprocessor to define the optimization problem. Because only a translation of ASCII-file
information about FE-discrimination, material constants, constrains and loads have to be performed
we can connect easily other preprocessors or CAD-programs.
8.2

Workflow from topology optimization, mesh smoothing and shape optimization up to the
CAD export

The following simple structure subjected to loads as shown in Fig. 11 is to be optimized using topology
and shape optimization. The user can define the areas that shall be subject to topology optimization
and areas that for any constructive reasons should not be modified. In Fig. 12, the modifiable
areas are colored green (lighter in black and with print).

Fig. 11: Example structure with load and support

conditions.

Fig. 12: Definition of modifiable (green) and

unchangeable (red) areas.

In the first step, the structure will now be subjected to topology optimization. In this case, the user has
defined the degree of material saving as 50%, stress and frequency constrains. The topology dialog is
shown in Fig. 13.

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Fig. 13 Topology optimization is simple defined by objective function, constrains and default
optimization parameters.
Fig. 14 shows the pseudo-density distribution calculated considering the given restraints. The resulting
non-smooth finite element mesh is displayed in Fig. 15.

Fig. 14: Pseudo-density distribution.

Fig. 15: Resulting finite element mesh.

After this, the finite element mesh is smoothed. Here, the user may define the surfaces to be
smoothed and the radius of smoothing (see Fig. 16).

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Fig. 16 Mesh smoothing dialog

The smoothed finite element mesh is shown in Fig. 17. The Von Mises stress distribution in the
obtained structure is shown in Fig. 18. As is to be seen, undesirable stress peaks occur. These shall
be eliminated in the following step via biological growth.

Fig. 17: Smoothed structure.

Fig. 18: Von Mises stress distribution in the

resulting structure.

Fig. 19 shows the necessary user interaction, choosing the number of iterations and a scaling
constant.

Fig. 19 Biological growth using pseudo-thermal strains

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In Fig. 20, the resulting Von Mises stress distribution after 3 steps of biological growth is shown in the
same scale as in Fig. 18. The last step to perform is the export of the faceted finite element surfaces in
any CAD software using STL. Fig. 21 shows the surface model of the optimized solid component.

Fig. 20: Resulting structure with Von Mises stress Fig. 21: STL based CAD export of the faceted
after biological growth.
surface of the solid component.

Conclusions
The presented software program TopoSLang is a very efficient tool for the topology and shape
optimization of solid components like massive tools. The software development focused to combine
sophisticated mathematical algorithms with a user-friendly GUI to support a continuous workflow. At
the moment the alpha development phase is completed. Within a short time a first commercial
version will be available via CAD-FEM.
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