A novel quasi-smooth tetrahedral numerical manifold method and its application in topology optimization based on parameterized level-set method

In this paper, a novel quasi-smooth tetrahedral numerical manifold method (NMM) and its two-dimensional (2D) counterpart are proposed. A new topology optimization method is established by combining the quasi-smooth manifold element (QSME) with the parameterized level set method (PLSM). The QSME introduces an innovative displacement function characterized by high accuracy and high-order continuity, effectively addressing the “linear dependence” (LD) issue inherent in traditional high-order NMM. To integrate QSME and PLSM, the corresponding optimization formulations and sensitivity analyses are provided. In order to fully utilize advantages of this novel quasi-smooth NMM and the PLSM, an element subdivision technique based on model recognition is proposed to accurately capture the physical boundaries. Additionally, a volume fraction update method based on element refinement is proposed. Taking advantage of the characteristics of the PLSM, a structure visualization method based on the sign distance function is developed to accurately describe curve boundary. This method allows for precise visualization of optimized structures. This study verifies high efficiency of the QSME-based PLSM for minimum compliance topology optimization problems in both 2D and 3D structures. Some representative structural optimization examples are tested to demonstrate effectiveness of the proposed method in both 2D and 3D problems, especially in complex design domain.