The optimization of porous infill structures via local volume constraints has become a popular approach in topology optimization. In some design settings, however, the iterative optimization process converges only slowly, or not at all even after several hundreds or thousands of iterations. This leads to regions in which a distinct binary design is difficult to achieve. Interpreting intermediate density values by applying a threshold results in large solid or void regions, leading to sub-optimal structures. We find that this convergence issue relates to the topology of the stress tensor field that is simulated when applying the same external forces on the solid design domain. In particular, low convergence is observed in regions around so-called trisector degenerate points. Based on this observation, we propose an automatic initialization process that prescribes the topological skeleton of the stress field into the density field as solid simulation elements. These elements guide the material deposition around the degenerate points, but can also be remodelled or removed during the optimization. We demonstrate significantly improved convergence rates in a number of use cases with complex stress topologies. The improved convergence is demonstrated for infill optimization under homogeneous as well as spatially varying local volume constraints.
We present a visualization technique for 2D stress tensor fields based on the construction of a globally conforming lattice. Conformity ensures that the lattice edges follow the principal stress directions and the aspect ratio of lattice elements represents the stress anisotropy. Since such a lattice structure cannot be space‐filling in general, it is constructed from multiple intersecting lattice beams. Conformity at beam intersections is ensured via a constrained optimization problem, by computing the aspect ratio of elements at intersections so that their edges meet when continued along the principal stress lines. In combination with a coloring scheme that encodes relative stress magnitudes, a global visualization is achieved. By introducing additional constraints on the positional variation of the beam intersections, coherent visualizations are achieved when external loads or material parameters are changed. In a number of experiments using non‐trivial scenarios, we demonstrate the capability of the proposed visualization technique to show the global and local structure of a given stress field.
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