Level-Set 3D Shape Optimization for Fatigue Loading Cycles
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Solution Overview
Problem
Current CAD software limitations in generative design for physical structures, particularly in addressing fatigue constraints and optimizing designs for multiple loading cycles, lead to suboptimal designs that may fail due to fatigue damage during repeated loading.
Innovation Solution
A computer-aided design program iteratively modifies a 3D shape based on design criteria, in-use load cases, and material specifications, using numerical simulations to assess stress and strain, and updates the shape through a level-set representation to ensure fatigue safety, converging to a stable solution that prevents catastrophic failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If detailed fatigue analysis is performed for each loading cycle, then fatigue safety is improved, but computational time and complexity increase
Solution Approach 1:
The patent applies parameter changes by transforming the detailed time-domain fatigue analysis into a frequency-domain or simplified damage parameter assessment. The system uses equivalent linearization techniques to convert complex nonlinear fatigue behavior into manageable parameters that can be evaluated efficiently during iterative design optimization.
Solution Approach 2:
The patent replaces the traditional mechanical step-by-step fatigue analysis with an equivalent energy-based or damage-parameter-based approach. By substituting detailed cycle-by-cycle stress analysis with simplified fatigue damage models, the system achieves comparable accuracy with significantly reduced computational effort.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures using generative design processes. A method includes obtaining a design space for a modeled object, one or more design criteria, one or more in-use load cases, and one or more specifications of material, wherein the design criteria comprise a required number of loading cycles for the modeled object; iteratively modifying a generatively designed three dimensional shape of the modeled object, comprising: performing numerical simulation of the modeled object, finding a maximized stress or strain element for each of the one or more in-use load cases, determining an expected number of loading cycles for each of the one or more in-use load cases, redefining a fatigue safety factor inequality constraint for the modeled object, computing shape change velocities in accordance with at least the fatigue safety factor inequality constraint, and updating the level-set representation.