An improved evolutionary structure optimization method considering stress minimization and smooth design

Abstract The design of continuum structures often presents challenges related to stress concentration, which can cause significant structural damage. To address this issue, the current study presents a new stress minimization method that utilizes the Windowed Evolutionary Structural Optimization (WESO) framework. The method aims to improve algorithm stability by optimizing design variables with an intermediate density. The use of a P‐norm stress aggregation method improves the assessment of global stress levels and enhances computational efficiency. Furthermore, a stable element sensitivity formulation, derived from the adjoint sensitivity analysis of the global stress measure, effectively handles the nonlinear stress behavior. Mesh filtering techniques are utilized to convert sensitivity from elements to nodes, and the structural topological solution is represented using the level set function (LSF) based on element‐node sensitivity. This method addresses the singularity issue commonly found in density‐based optimization methods and facilitates the achievement of smooth topological solutions. Through 2D and 3D benchmark designs, the proposed method's feasibility, stability, and superiority are thoroughly demonstrated. A parametric study is conducted to identify the optimal parameter range for the algorithm, leading to the development of a rational method for parameter selection. The optimized topology, with its smooth boundaries, can guide the design of structures without the need for redesign or post‐processing, helping to drive innovation and development in engineering.