Shape optimization method for strength design problem of microstructures in a multiscale structure

Abstract In this paper, we propose a solution to a shape optimization problem for the strength design of periodic microstructures in multiscale structures. Two maximum stress minimization problems are addressed: minimization of maximum microstructural stress and minimization of maximum macrostructural stress. The homogenization method is used to bridge the macrostructure and the microstructure and to calculate local microstructural stress. By replacing the maximum stress value with a Kreisselmeier‐Steinhauser function, the difficulty of nondifferentiability of maximum stress is avoided. Each strength design problem is formulated as a distributed parameter optimization problem subject to an area constraint including the whole microstructure. The shape gradient functions for both problems are derived using Lagrange's undetermined multiplier method, the material derivative method, and the adjoint variable method. The H 1 gradient method is used to determine the unit cell shapes of the microstructure, while reducing the objective function and maintaining smooth design boundaries. In the numerical examples, the optimal shapes obtained for minimization of the maximum local stress of the microstructure and the macrostructure are compared and discussed. The results confirm the effectiveness of the microstructure shape optimization method for the two strength design problems of multiscale structures.