OENG1189-Project 2

Optimizing a reinforcement structure member for an existing building using sensitivity-based topology optimization

Due date: 5 October 2025

Assessment submission file: PDF file preferred with a link to your video and an obj file

Assessment submission types:  Online submission for each student

1. Brief Introduction of the Project

You are required to conduct a topology optimization for a Reinforcement Structure (RS) to reinforce  the  connections  of  a  space  station,  one  connection  is  illustrated  in  Figure   1 surrounded by red dash line.   The location of this building is in near earth  orbit (not real, imaginary).

Figure 1 Space station to be repaired through reinforcement structural design

Due  to   design  and  services,  the  connecting  arms  between   centre  and  circumferential chambers  need  to  be  reinforced.  One  connecting  arm  to  link  the  outside  chamber  ring becomes  much  less  stiff than  other  connections  and  should  be  reinforced  by  additional supporting structure. A simplified 2D model is available on Canvas for you to measure and check your design as illustrated in Figure 2. The relative density of the equivalent aluminium alloy structure can be considered as 0.05. Thus, the equivalent material properties of the aluminium alloy are E=0.05*60GPa=3GPa, v=0.1, and the yield stress of base aluminium alloy is 300MPa, the equivalent one can be considered as 15MPa.

You should consider the following solutions:

1.   Identifying  the  critical  design  load  for  your  optimization  design  by  considering maximum  deflection  on  weakened  tunnel  through  varying  the  directions  of  the parking load (k*5000kN) combined with inertia load (500kN along radial direction and 5000kN along circumferential direction);

2.   Provide  an  optimal  design  for  the  RS  for  the  one  connection  similar  to  that  as highlighted by the red lines in Figure 2;

3.   Provide an optimal design for the RS for the whole 4 connections if they are all

weakened with similar and different weakened level ( which is achieved by varying area of void as weakened stiffness);

4.   Provide optimal design with different available materials;

5.   Provide related evidence to illustrate the accuracy and merits of your design.

Figure 2. Simplified 2D structure for your optimization design.

Figure 3. Personalize your weakened tunnel (Showing as grey area in Figure 2)

You should personalize the location of weakened section (indicated by shaded area in Figure 3) with your student number. The left location will be 26m + last two digits of your student number/10.  For  example,  if  your  student  number  is  3345568,  then  the  left  location  is (26+6.8=)32.8m  from the centre. The right location is 72m + middle two digits of your student number (for previous example, 72+5.5=77.5m). The magnitude of the parking load is k  times  the  inertia  load  along  circumferential  direction.  (k=0.8+first  two  digits  of your student no after S3 and divide by 100. For the given example, k=0.8+34/100=1. 14).

If you work in a group, you should average the student number of all group members.

2. Optimisation Design Requirements

2.1 Optimisation problem:

Following  the  procedures  for  an  optimisation  design,  you  are  expected  to  provide  the following information for your optimisation design based on your understanding.

•    Site surveying by checking the SpaceStation3D.cae

•   Identify the critical load case for your optimization design using 2D FEMs ofthe Space Station

•   Define design domain, objectives, constraints, optimization statement

•   Obtain optimization design using BESO2D software

•   Verify and validate the optimal design using right FEM (note that the requirements are slightly different for RS structure) and render best design on site

•   Changing the material of your design, filter radius to obtain at least 6 innovative

designs (only one set of verification of validation process ofFEM and OD should be presented in the report, other innovative designs only present their final rendered view on site).

It should be noted, the original statement of the optimization problem and the equivalent statement which can be done using BESO2D software should be included in the report.

2.2 Intended construction method and materials

The RS will be constructed by 3D printer. You may consider different materials to be used as the RS such as

•   Aluminium (equivalent one with 5% relative density similar to the one used in the FEM provided)

•   Plastics

•   other identified available printing materials

The minimum requirement is to consider equivalent aluminium and plastic.

2.3 Intended optimisation tool

•   BESO2D software (preferred)

•   MATLAB code (with simplified boundary)

2.4 Intended FEM to check the performance of the different innovative design:

•   Verify and validate only one FEM with one optimal topology from BESO2D software or MATLAB code

•   Using  SpaceStation2D_Reinforced.cae  and  replace  the  existing  reinforcement  part with your innovative design;

•   Compare the displacement contour and Mises stress contour of the connections from above FEM with that from the SpaceStation2D_CReinforce.cae;

•   Check the possible failure of material used for the RS using maximum tensile strength or Von Mises stress level as criteria.

All related FEMs will be available on Canvas in Week 7.

Figure 4. Simplified 3D structure for visualization of your optimization design.

3. Expected Results of the Project

•   Concise Finite Element Analysis (FEA) procedure for the FEM with optimal topology from BESO2D software with less screen shot as possible;

•   At least two optimal designs ofthe RS to reinforce for 1 weakened connection and for 4 connections;

•   Evidence to prove the accuracy of your design;

•   A 3D rendering using the 3D model provided as illustrated in Figure 4;

•   You will provide the merits of your design to persuade the customer to accept your design as the final solution;

•   Prepare an OBJ file of a scaled model with your optimal design for 3D printing with any commercial services available to you. (Students in a group should have different 3D model in this obj file).

4. Detailed Requirements of the Project:

In your report, you should provide evidence (Screen shot, table for data input, sketch, charts etc) to show the completion of the following required tasks for Project 2:

4.1 Structural Optimization:

1. Overall procedure for your optimisation design

2. Optimization statements;

3. Presenting the base optimal results;

4. Variations on topology patterns to represent weakened connections, reinforcing materials; refined sizes of design domain including hierarchical design etc to obtain different innovative designs;

5. Provide 3D rendering of all innovative designs and their corresponding merits;

6. Provide reasons based on merits of designs to persuade customers or 3D construction company to accept your innovative designs as a final solution.

4.2 FEA modelling information of one of your optimal reinforcement structures

You should do this using the one connection with the RS or the RS for all connections to illustrate FEA process and output one set of detailed FEA results.

1. Geometry modelling of optimal RS (only one part in your Abaqus/Assembly) (overall sizes, key angles, width of key members etc)

2. Material model and corresponding parameters used for your designs;

3. Loading conditions, boundary conditions and interactions;

4. Meshing information;

5. FEM verification (Only RS structure is in FEM and Software report, energy balance, force equilibrium, following expectations and mesh convergence check);

6. FEM validation through using initiative design

(Using the similar topology to the initial design for RS structure in FEM provided SpaceStation2D_CReinforce.cae to validate your FEM).

4.3 Brief marking rules

The total mark of this assignment 2 is 30 marks. There will 5 criteria to mark this assignment.

Criteria 1 - Accuracy. The modelling information, procedures and results are accurate.

Criteria 2 - Completeness.  All required tasks should be completed for this project 2.

Criteria 3 - Professional Report. The report is written in a professional way.

Criteria 4 - Innovative Designs and Merits. Different designs with corresponding merits should be provided for customers to choose from.

Criteria 5 - Video Presentation.

This is an assignment for an individual student or a group of students up to 5 members. It is your choice to do it by yourself or do it with a group. Every student should submit a separate report on canvas.

If you work with a group work, you should form a group on Canvas and add a statement of contributions from each member in the group in your report.

More detailed information to earn marks can be found in the detailed marking rubrics as attached at the end of this assignment illustration.

Penalty for late submission of the project:

Late submission of this assignment will incur a penalty of 10% of total mark of this assignment each date after the due date.