CutFEM topology optimization of 3D laminar incompressible flow problems

This paper studies the characteristics and applicability of the CutFEM approach [1] as the core of a robust topology optimization framework for 3D laminar incompressible flow and species transport problems at low Reynolds number (Re < 200). CutFEM is a methodology for discretizing partial differential equations on complex geometries by immersed boundary techniques. In this study, the geometry of the fluid domain is described by an explicit level set method, where the parameters of a level set function are defined as functions of the optimization variables. The fluid behavior is modeled by the incompressible Navier-Stokes equations. Species transport is modeled by an advection-diffusion equation. The governing equations are discretized in space by a generalized extended finite element method. Face-oriented ghost-penalty terms are added for stability reasons and to improve the conditioning of the system. The boundary conditions are enforced weakly via Nitsche’s method. The emergence of isolated volumes of fluid surrounded by solid during the optimization process leads to a singular analysis problem. An auxiliary indicator field is modeled to identify these volumes and to impose a constraint on the average pressure. Numerical results for 3D, steady-state and transient problems demonstrate that the CutFEM analyses are sufficiently accurate, and the optimized designs agree well with results from prior studies solved in 2D or by density approaches.