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We present a topology optimization method based on the geometry projection technique for the design of frames made of structural shapes. An equivalent-section approach is formulated that represents the cross-section of the structural shapes as a homogeneous rectangular section. The accuracy of this approach is demonstrated by comparison to analyses performed using body-fitted meshes of the original sections for different loads and boundary conditions. A novel geometric representation is also introduced to represent the equivalent section as a cuboid. Like offset solids, this representation is endowed with an explicit expression for the computation of the signed distance to the boundary of the primitive and of its sensitivities, allowing for an efficient implementation. An overlap constraint is imposed via the formulation of auxiliary primitives associated to the structural members, which guarantees the resulting designs do not exhibit impractical intersections of primitives that would preclude their construction. The efficacy and efficiency of the method is demonstrated via 2D and 3D design examples. The examples demonstrate that the proposed method renders optimal designs and exhibits good convergence. They also illustrate the ability to design structures with far lower optimal volume fractions than those typically employed in continuum topology optimization techniques. 

Abstract This work presents a method for the topology optimization of welded frame structures to minimize the manufacturing cost. The structures considered here consist of assemblies of geometric primitives such as bars and plates that are common in welded frame construction. A geometry projection technique is used to map the primitives onto a continuous density field that is subsequently used to interpolate material properties. As in density-based topology optimization techniques, the ensuing ersatz material is used to perform the structural analysis on a fixed mesh, thereby circumventing the need for re-meshing upon design changes. The distinct advantage of the representation by geometric primitives is the ease of computation of the manufacturing cost in terms of the design parameters, while the geometry projection facilitates the analysis within a continuous design region. The proposed method is demonstrated via the manufacturing-cost-minimization subject to a displacement constraint of 2D bar, 3D bar, and plate structures. 

Topology optimization problems are typically non-convex, and as such, multiple local minima exist. Depending on the initial design, the type of optimization algorithm and the optimization parameters, gradient-based optimizers converge to one of those minima. Unfortunately, these minima can be highly suboptimal, particularly when the structural response is very non-linear or when multiple constraints are present. This issue is more pronounced in the topology optimization of geometric primitives, because the design representation is more compact and restricted than in free-form topology optimization. In this paper, we investigate the use of tunneling in topology optimization to move from a poor local minimum to a better one. The tunneling method used in this work is a gradient-based deterministic method that finds a better minimum than the previous one in a sequential manner. We demonstrate this approach via numerical examples and show that the coupling of the tunneling method with topology optimization leads to better designs.