Optimal structures for failure resistance under impact

The complex physics and numerous failure modes of structural impact creates challenges when designing for impact resistance. While simple geometries of layered material are conventional, advances in 3D printing and additive manufacturing techniques have now made tailored geometries or integrated multi-material structures achievable. Here, we apply gradient-based topology optimization to the design of such structures. We start by constructing a variational model of an elastic-plastic material enriched with gradient phase-field damage, and present a novel method to efficiently compute its transient dynamic time evolution. We consider a finite element discretization with explicit updates for the displacements. The damage field is solved through an augmented Lagrangian formulation, splitting the operator coupling between the nonlinearity and non-locality. Sensitivities over this trajectory are computed through the adjoint method, and we develop a numerical method to solve the resulting adjoint dynamical system. We demonstrate this formulation by studying the optimal design of 2D solid-void structures undergoing blast loading. Then, we explore the trade-offs between strength and toughness in the design of a spall-resistant structure composed of two materials of differing properties undergoing dynamic impact.

Automated summary

Designing for impact resistance is challenging due to the complex physics and failure modes involved. Recent advances in 3D printing and additive manufacturing techniques allow for tailored geometries and multi-material structures. This study applies gradient-based topology optimization to design such structures, and presents efficient methods for computing their transient dynamic evolution. By studying the optimal design of solid-void structures and spall-resistant structures, the trade-offs between strength and toughness are explored.