Design of fracture resistant energy absorbing structures using elastoplastic topology optimization

This paper introduces a novel elastoplastic topology optimization method for fracture resistant energy absorbing structural designs. The target is to find the optimal structural topologies with high plastic work absorption capacity while constraining the fracture indicators below the prescribed constraints. As the two main fracture mechanisms in ductile metals, the ductile fracture and shear fracture criteria are considered using uncoupled CrachFEM fracture model. A consistent adjoint method is presented for the path-dependent sensitivity analysis under the plane stress assumption. Several numerical examples are carried out to demonstrate the effectiveness of the proposed method. It is shown that by constraining the fracture indicators, the optimized designs have a more uniform plastic work distribution and high ductility with a significant delay of failure points. This eventually leads to much better material utilization with enhanced ultimate energy absorption capacities.

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