Thermo-mechanical coupled topology optimization for sandwich structures with non-uniform infill

TY - JOUR

T1 - Thermo-mechanical coupled topology optimization for sandwich structures with non-uniform infill

AU - Bai, Yingchun

AU - Wang, Tao

AU - Gao, Jiayu

AU - Ji, Wei

AU - Chen, Yuan

AU - He, Hongwen

N1 - Publisher Copyright: © 2025 Elsevier Ltd

PY - 2025/11

Y1 - 2025/11

N2 - This study presents a thermo-mechanical coupled topology optimization framework for designing sandwich structures with non-uniform infill, which will fully explore the sandwich structural multi-functionality related to load-carrying and thermal conduction. By using two design variable fields, the fundamental sandwich topology is formulated through two-step density filtering and local volume constraint. The compliance minimization topology optimization model is constructed with both material usage and maximum temperature constraints in combination with weak thermo-mechanical coupled analysis. Corresponding sensitivities are derived into optimizer to update the topology. Several numerical examples are investigated to demonstrate the effectiveness of the proposed method in combination with different parameter setting. Finally, the proposed method is used to design the power battery module bracket.

AB - This study presents a thermo-mechanical coupled topology optimization framework for designing sandwich structures with non-uniform infill, which will fully explore the sandwich structural multi-functionality related to load-carrying and thermal conduction. By using two design variable fields, the fundamental sandwich topology is formulated through two-step density filtering and local volume constraint. The compliance minimization topology optimization model is constructed with both material usage and maximum temperature constraints in combination with weak thermo-mechanical coupled analysis. Corresponding sensitivities are derived into optimizer to update the topology. Several numerical examples are investigated to demonstrate the effectiveness of the proposed method in combination with different parameter setting. Finally, the proposed method is used to design the power battery module bracket.

KW - Non-uniform infill

KW - Sandwich structure

KW - Temperature constraint

KW - Thermo-mechanical coupled

KW - Topology optimization

UR - https://www.scopus.com/pages/publications/105009987348

U2 - 10.1016/j.tws.2025.113647

DO - 10.1016/j.tws.2025.113647

M3 - Article

AN - SCOPUS:105009987348

SN - 0263-8231

VL - 216

JO - Thin-Walled Structures

JF - Thin-Walled Structures

M1 - 113647

ER -