An improved on/off method with a two-step surface smoother for topology optimization of electromagnetic devices

Purpose Topology optimization is a state-of-the-art technique for the innovative design of electromagnetic devices. The ON/OFF method is a typical approach for this purpose. However, the drawbacks of long iteration time and poor ability to express curved surfaces make the industry not shown their due interest so far in the ON/OFF method. The purpose of this paper is to study a novel ON/OFF method for topology optimization, which can bring feasible optimized shapes that are more friendly for industrial realization in a shorter time. Design/methodology/approach The proposed improved ON/OFF method uses structured triangular elements for finite element modeling because the triangular elements can more freely express shape features. Every four triangular elements are pieced together to form a square cell, each quadrilateral cell is associated with a binary value indicating the material state of the four triangular elements. The binary metaheuristic algorithms are used to optimize the material distribution. After the material filling for the elements based on the output of the metaheuristic algorithm, a two-step surface smoother will be performed as the postprocess to make the shapes more friendly for manufacturing. Findings The comparative numerical results on a benchmark topology optimization problem show that the proposed method can bring feasible optimized shapes that are more friendly for industrial realization in a shorter time. In addition, the speed and robustness of convergence, especially in the case of multiobjective topology optimization problem, are significantly improved. Originality/value A novel ON/OFF method for topology optimization is proposed. Compared with the traditional ON/OFF method, the proposed method is better in terms of searching efficiency and robustness. Moreover, the proposed method can provide feasible optimized shapes that are more friendly for industrial realization.