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Summary This paper extends current concepts of topology optimization to the design of structures made of nonlinear microheterogeneous materials. The objective is to maximize the macroscopic structural stiffness for a prescribed material volume usage while accounting for the nonlinearity and the microstructure of the material. The resulting design problem considers two scales: the macroscopic scale at which the optimization is performed and the microscopic scale at which the material heterogeneities and the nonlinearities are observed. The topology optimization at the macroscopic scale is performed by means of the bi‐directional evolutionary structural optimization method. The solution of the macroscopic boundary value problem requires as inputs the effective constitutive response with full consideration of the microstructure. While computational homogenization methods such as the FE2 method could be used to solve the nonlinear multiscale problem, the associated numerical expense (CPU time and memory) is highly unacceptable. In order to regain the computational feasibility of the computational scale transition, a recent model reduction technique of the authors is employed: the potential‐based reduced basis model order reduction with graphics processing unit acceleration. Numerical examples show the efficiency of the resulting nonlinear two‐scale designs. The impact of different load amplitudes on the design is examined. Copyright © 2015 John Wiley & Sons, Ltd.

The mechanical response of composite materials is strongly influenced by the nonlinear behavior of the interface between the constituents. In order to make reliable yet computationally efficient predictions for such materials, a reduced order model is developed. Conceptual ideas of the NTFA (Michel and Suquet, Int J Solids Struct 40: 6937-6955, 2003, Comput Methods Appl Mech Eng 193:5477-5502, 2004) and of the pRBMOR Leuschner Comput Methods Appl Mech Eng 260:143-154, 2013, Fritzen et al., Comput Methods Appl Mech Eng 278:186-217, 2014) are adopted. The key idea is to parameterize the displacement jumps on the cohesive interfaces by a reduced basis of global ansatz functions. Micromechanical considerations and the potential structure of the constitutive models lead to a variational formulation and reduced equilibrium conditions. The effect of the preanalysis phase on the accuracy is investigated using geometrically optimal training directions. The reduced model is tested for three-dimensional microstructures. Besides the effective stress response, the tension-compression asymmetry and the distribution of the separation of the interface are investigated. Memory savings on the order of 10 5 are realized. The computing time is reduced considerably. asymmetry · Potential-based reduced basis model order reduction (pRBMOR)