Topology optimization of structures: A minimum weight approach with stress constraints

Sizing and shape structural optimization problems are normally stated in terms of a minimum weight approach with constraints that limit the maximum allowable stresses and displacements. However, topology structural optimization problems have been usually stated in terms of a maximum stiffness (minimum compliance) approach. In this kind of formulations, the aim is to distribute a given amount of material in a certain domain, so that the stiffness of the resulting structure is maximized (the compliance, or energy of deformation, is minimized) for a given load case. Thus, the material mass is restricted to a predefined percentage of the maximum possible mass, while no stress or displacement constraints are taken into account. In this paper we analyze and compare both approaches, and we present a FEM minimum weight with stress constraints (MWSC) formulation for topology structural optimization problems. This approach does not require any stabilization technique to produce acceptable optimized results, while no truss-like final solutions are necessarily obtained. Several 2D examples are presented. The optimized solutions seem to be correct from the engineering point of view, and their appearence could be considered closer to the engineering intuition than the traditional truss-like results obtained by means of the widespread maximum stiffness (minimum compliance) approaches.