Computational design of auxetic microstructures via stress-based topology

Material design plays a pivotal role in industries dedicated to lightweight manufacturing. In response to the needs of such industries, topology optimization (TO) has evolved beyond structural optimization to include designing material microstructures for improved structural performance. While conventional approaches often prioritize stiffness-oriented designs as a foundational aspect of structural integrity, it is equally imperative to emphasize strength-based design principles to ensure robustness against localized stress concentrations and potential failure modes. This paper explores the application of stress-constrained topology optimization (SCTO) for designing auxetic microstructures. The study commences with a comprehensive parametric analysis to examine the influence of the P-norm parameter, variations in volume fraction, and initial design adjustments on the resulting microstructures. Several optimized structures, accompanied by stress contours, are generated to showcase how the optimization process responds to these parameters. The approach employs the density-based solid isotropic material with penalization material interpolation scheme, and it utilizes the stress penalization technique to mitigate the singularity phenomenon. The multi-constraint optimization employs the method of moving asymptotes algorithm to update design variables. The effectiveness of the proposed approach to utilize actual strain fields, derived from macroscopic finite element analysis under service loads, for TO of an auxetic microstructure according to strength requirements is demonstrated. The application of the designed microstructure is explored through its integration into an auxetic cushion pad. This analysis confirms the microstructure's effectiveness in practical applications, demonstrating its potential for broader usage in similar applications.