A review of flexible multibody dynamics for gradient-based design optimization

Abstract Design optimization of flexible multibody dynamics is critical to reducing weight and therefore increasing efficiency and lowering costs of mechanical systems. Simulation of flexible multibody systems, though, typically requires high computational effort which limits the usage of design optimization, especially when gradient-free methods are used and thousands of system evaluations are required. Efficient design optimization of flexible multibody dynamics is enabled by gradient-based optimization methods in concert with analytical sensitivity analysis. The present study summarizes different formulations of the equations of motion of flexible multibody dynamics. Design optimization techniques are introduced, and applications to flexible multibody dynamics are categorized. Efficient sensitivity analysis is the centerpiece of gradient-based design optimization, and sensitivity methods are introduced. The increased implementation effort of analytical sensitivity analysis is rewarded with high computational efficiency. An exemplary solution strategy for system and sensitivity evaluations is shown with the analytical direct differentiation method. Extensive literature sources are shown related to recent research activities.