Automatic reconstruction of beam structures from 3D topology optimization results

This paper presents a fully-automated reconstruction of beam-like CAD solid structures from 3D topology optimization (TO) results. Raw TO results are first processed to generate a triangulation that represents boundaries of the optimal shape derived. This triangulation is then smoothed and a curve skeletonization procedure is carried out to recover meaningful characteristics of this smoothed triangulation. The resulting skeleton, made with curvilinear geometry, is transformed into straight lines through a normalization process. These straight lines are used to generate a 3D beam structure. Thus, following these steps, a 3D beam structure is automatically derived from TO results. This 3D beam structure is meshed with beam finite elements and since TO non-design material is represented by 3D solid geometry, which is meshed using tetrahedron, the FEA beam structure needs to be rigidly connected with these tetrahedrons. Rigid connections between beam elements and 3D solid elements are ensured using specific FEA beam elements referred to as mini-beams. This results in a mixed-dimensional FEA model with beam and solid finite elements. Results obtained with this mixed-dimensional FEA model allow validating the beam structure obtained from TO results. Performance of the approach is demonstrated on several TO examples.