A strategy for density-based topology optimization of fluid-structure interaction problems is proposed that deals with some shortcomings associated to non stiffness-based design. The goal is to improve the passive aerodynamic shape adaptation of highly compliant airfoils at multiple operating points. A two-step solution process is proposed that decouples global aeroelastic performance goals from the search of a solid-void topology on the structure. In the first step, a reference fully coupled fluid-structure problem is solved without explicitly penalizing non-discreteness in the resulting topology. A regularization step is then performed that solves an inverse design problem, akin to those in compliant mechanism design, which produces a discrete-topology structure with the same response to the fluid loads. Simulations are carried out with the multi-physics suite SU2, which includes Reynolds-averaged Navier-Stokes modeling of the fluid and hyper-elastic material behavior of the geometrically nonlinear structure. Gradient-based optimization is used with the exterior penalty method and a large-scale quasi-Newton unconstrained optimizer. Coupled aerostructural sensitivities are obtained via an algorithmic differentiation based coupled discrete adjoint solver. Numerical examples on a compliant aerofoil with performance objectives at two Mach numbers are presented.

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This article presents a methodology whereby adjoint solutions for partitioned multiphysics problems can be computed efficiently, in a way that is completely independent of the underlying physical sub-problems, the associated numerical solution methods, and the number and type of couplings between them. By applying the reverse mode of algorithmic differentiation to each discipline, and by using a specialized recording strategy, diagonal and cross terms can be evaluated individually, thereby allowing different solution methods for the generic coupled problem (for example block-Jacobi or block-Gauss-Seidel). Based on an implementation in the open-source multiphysics simulation and design software SU2, we demonstrate how the same algorithm can be applied for shape sensitivity analysis on a heat exchanger (conjugate heat transfer), a deforming wing (fluid–structure interaction), and a cooled turbine blade where both effects are simultaneously taken into account.

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