This paper presents for the first time an adaptive immersed approach for level-set topology optimization using higher-order truncated hierarchical B-spline discretizations for design and state variable fields. Boundaries and interfaces are represented implicitly by the iso-contour of one or multiple level-set functions. An immersed finite element method, the eXtended IsoGeometric Analysis, is used to predict the physical response. The proposed optimization framework affords different adaptively refined higher-order B-spline discretizations for individual design and state variable fields. The increased continuity of higher-order B-spline discretizations together with local refinement enables direct control over the accuracy of the representation of each field while simultaneously reducing computational cost compared to uniformly refined discretizations. A flexible mesh adaptation strategy enables local refinement based on geometric measures or physics-based error indicators. These adaptive discretization and analysis approaches are integrated into gradient-based optimization schemes, evaluating the design sensitivities using the adjoint method. Numerical studies illustrate the features of the proposed framework with static, linear elastic, multi-material, two- and three-dimensional problems. The examples provide insight into the effect of refining the design variable field on the optimization result and the convergence rate of the optimization process. Using coarse higher-order B-spline discretizations for level-set fields promotes the development of smooth designs and suppresses the emergence of small features. Moreover, adaptive mesh refinement for state variable fields results in a reduction of overall computational cost. Higher-order B-spline discretizations are especially interesting when evaluating gradients of state variable fields due to their higher inter-element continuity.

In topology optimization of transient problems, memory requirements and computational costs often become prohibitively large due to the backward-in-time adjoint equations. Common approaches such as the Checkpointing (CP) and Local-in-Time (LT) algorithms reduce memory requirements by dividing the temporal domain into intervals and by computing sensitivities on one interval at a time. The CP algorithm reduces memory by recomputing state solutions instead of storing them. This leads to a significant increase in computational cost. The LT algorithm introduces approximations in the adjoint solution to reduce memory requirements and leads to a minimal increase in computational effort. However, we show that convergence can be hampered using the LT algorithm due to errors in approximate adjoints. To reduce memory and/or computational time, we present two novel algorithms. The hybrid Checkpointing/Local-in-Time (CP/LT) algorithm improves the convergence behavior of the LT algorithm at the cost of an increased computational time but remains more efficient than the CP algorithm. The Parallel-Local-in-Time (PLT) algorithm reduces the computational time through a temporal parallelization in which state and adjoint equations are solved simultaneously on multiple intervals. State and adjoint fields converge concurrently with the design. The effectiveness of each approach is illustrated with two-dimensional density-based topology optimization problems involving transient thermal or flow physics. Compared to the other discussed algorithms, we found a significant decrease in computational time for the PLT algorithm. Moreover, we show that under certain conditions, due to the use of approximations in the LT and PLT algorithms, they exhibit a bias toward designs with short characteristic times. Finally, based on the required memory reduction, computational cost, and convergence behavior of optimization problems, guidelines are provided for selecting the appropriate algorithms.

Solving conjugate heat transfer design problems is relevant for various engineering applications requiring efficient thermal management. Heat exchange between fluid and solid can be enhanced by optimizing the system layout and the shape of the flow channels. As heat is transferred at fluid/solid interfaces, it is crucial to accurately resolve the geometry and the physics responses across these interfaces. To address this challenge, this work investigates for the first time the use of an eXtended Finite Element Method (XFEM) approach to predict the physical responses of conjugate heat transfer problems considering turbulent flow. This analysis approach is integrated into a level set-based optimization framework. The design domain is immersed into a background mesh and the geometry of fluid/solid interfaces is defined implicitly by one or multiple level set functions. The level set functions are discretized by higher-order B-splines. The flow is predicted by the Reynolds Averaged Navier–Stokes equations. Turbulence is described by the Spalart–Allmaras model and the thermal energy transport by an advection–diffusion model. Finite element approximations are augmented by a generalized Heaviside enrichment strategy with the state fields being approximated by linear basis functions. Boundary and interface conditions are enforced weakly with Nitsche’s method, and the face-oriented ghost stabilization is used to mitigate numerical instabilities associated with the emergence of small integration subdomains. The proposed XFEM approach for turbulent conjugate heat transfer is validated against benchmark problems. Optimization problems are solved by gradient-based algorithms and the required sensitivity analysis is performed by the adjoint method. The proposed framework is illustrated with the design of turbulent heat exchangers in two dimensions. The optimization results show that, by tuning the shape of the fluid/solid interface to generate turbulence within the heat exchanger, the transfer of thermal energy can be increased.

This paper presents an immersed, isogeometric finite element framework to predict the response of multi-material, multi-physics problems with complex geometries using locally refined discretizations. To circumvent the need to generate conformal meshes, this work uses an extended finite element method (XFEM) to discretize the governing equations on non-conforming, embedding meshes. A flexible approach to create truncated hierarchical B-splines discretizations is presented. This approach enables the refinement of each state variable field individually to meet field-specific accuracy requirements. To obtain an immersed geometry representation that is consistent across all hierarchically refined B-spline discretizations, the geometry is immersed into a single mesh, the XFEM background mesh, which is constructed from the union of all hierarchical B-spline meshes. An extraction operator is introduced to represent the truncated hierarchical B-spline bases in terms of Lagrange shape functions on the XFEM background mesh without loss of accuracy. The truncated hierarchical B-spline bases are enriched using a generalized Heaviside enrichment strategy to accommodate small geometric features and multi-material problems. The governing equations are augmented by a formulation of the face-oriented ghost stabilization enhanced for locally refined B-spline bases. We present examples for two- and three-dimensional linear elastic and thermo-elastic problems. The numerical results validate the accuracy of our framework. The results also demonstrate the applicability of the proposed framework to large, geometrically complex problems.

Multi-material problems often exhibit complex geometries along with physical responses presenting large spatial gradients or discontinuities. In these cases, providing high-quality body-fitted finite element analysis meshes and obtaining accurate solutions remain challenging. Immersed boundary techniques provide elegant solutions for such problems. Enrichment methods alleviate the need for generating conforming analysis grids by capturing discontinuities within mesh elements. Additionally, increased accuracy of physical responses and geometry description can be achieved with higher-order approximation bases. In particular, using B-splines has become popular with the development of IsoGeometric Analysis. In this work, an eXtended IsoGeometric Analysis (XIGA) approach is proposed for multi-material problems. The computational domain geometry is described implicitly by level set functions. A novel generalized Heaviside enrichment strategy is employed to accommodate an arbitrary number of materials without artificially stiffening the physical response. Higher-order B-spline functions are used for both geometry representation and analysis. Boundary and interface conditions are enforced weakly via Nitsche’s method, and a new face-oriented ghost stabilization methodology is used to mitigate numerical instabilities arising from small material integration subdomains. Two- and three-dimensional heat transfer and elasticity problems are solved to validate the approach. Numerical studies provide insight into the ability to handle multiple materials considering sharp-edged and curved interfaces, as well as the impact of higher-order bases and stabilization on the solution accuracy and conditioning.