Topology optimization with buckling constraints: Adaptive eigenvalue aggregation and modality identification

Abstract: This paper presents novel approaches to tackle two key challenges in topology optimization problems with buckling constraints: determining how many eigenvalues to aggregate and identifying the eigenvalue modality at the optimal design. We demonstrate the mathematical inconsistencies that arise when choosing an arbitrary fixed number of eigenvalues for aggregation. Specifically, if the multiplicity of the critical eigenvalues is smaller than the chosen subset size, coalescence with higher-order eigenvalues can occur. Neglecting these during aggregation causes incorrect sensitivities, while simply increasing the preselected eigenvalue count unnecessarily raises computational costs. To resolve this issue, we propose an approach that dynamically determines the exact number of eigenvalues required at each optimization iteration. The proposed approach reduces computation time significantly while maintaining competitive performance relative to the conventional method across the numerical experiments presented. Additionally, accurately predicting modality at the optimal point is crucial for understanding the buckled mode shapes of optimized designs. A new optimization formulation is proposed using the difference between eigenvalues to capture the true eigenvalue modality. This formulation is first validated on a classical 1D clamped column, successfully predicting both the bimodal solution and the optimal eigenvectors. The approach demonstrates that the optimal solutions for the wall reinforcement and shear-loaded hinged plate problems for the given set of parameters are trimodal and tetramodal, respectively.