Shape derivatives in bi-material level-set optimization with a precise interface: a comparative study

Abstract In this study, we investigate and compare formulations for computing shape derivatives in bi-material level-set optimization with precise modeling of the interface. The level-set function is parameterized using B-splines, whose coordinates serve as design variables. A precise analysis model is obtained every design cycle, replicating the exact geometry of the bi-material design, using untrimming techniques and IGA on unstructured meshes. Design sensitivities are formulated by either a “discretize-then-differentiate” or a “differentiate-then-discretize” approach. A detailed comparative study shows the limitations of the latter in terms of accuracy, specifically when stresses near the material interface dominate the stress field. The precise representation of the interface facilitates an accurate evaluation of interfacial stresses, and the consistent discretized sensitivities enable to minimize them directly – highlighting the main advantage of our framework. Furthermore, reducing the discretized approach by considering only interface control points and a selective set of adjacent control points provides an ideal trade-off between accuracy and numerical efficiency. This lays the foundations for multi-material shape and topology optimization procedures, considering accurate responses on the interface.