Concurrent two-scale topological design of multiple unit cells and structure using combined velocity field level set and density model

This paper studies concurrent two-scale design optimization of composite structures filled with multiple microstructural unit cells. The task of the design problem is to simultaneously optimize microstructural configurations of the unit cells and their spatial distribution in the macroscale. To this end, a new topology optimization framework based on combined topology representation of the density model and the level set model is proposed. The homogenization method is used to link the material microstructural design and the macroscale design by evaluating the effective properties of the microstructures. In the microscale, topology optimization of multiple microstructural unit cells is performed with the density-based method. In the macroscale design, the distribution of multiple microstructural unit cells is optimized by the velocity field level set method, which inherits advantages of the implicit geometrical representation of the conventional level set model (relatively clear and smooth material boundaries/interfaces, more natural description of topological evolution). Moreover, the velocity field level set method maps the variational boundary shape optimization problem into a finite-dimensional design space, thus making it relatively easy and efficient to employ general mathematical programming algorithms to handle the multiple constraints and two types of design variables in the concurrent two-scale design problem. Numerical examples show that the present concurrent two-scale design method can generate meaningful designs of hierarchical cellular structures with well-defined boundaries and material interfaces. •A concurrent two-scale design of multiple unit cells and structure is presented.•VFLS and SIMP method are respectively used in macroscale and microscale designs.•Level set model gives a rigorous interpretation of microstructure distribution.•VFLS method can efficiently handle multiple constraints in multiscale design.•Using multiple unit cells can obtain higher structural stiffness than uniform ones.