Investigation on the Improvement of Geogrid Performance Based on Topology Optimization of Aperture Shape

Geogrids significantly enhance the soil matrix stability and foundation bearing capacity. Despite the development of numerous geogrid configurations, their geometric design has not yet been systematically optimized. The design of geogrid aperture geometry aims to maximize geogrid performance while maintaining material efficiency. Nevertheless, topology optimized geogrid designs remain underexplored, particularly regarding the influence of aperture shape on interface shear behavior. To address this gap, this study developed SIMP-based variable density topology optimization models for three types of tensile geogrid structures: uniaxial, biaxial, and triaxial geogrid. The effects of key model parameters on the optimization results are examined, resulting in new geogrid geometries optimized primarily to minimize compliance, achieving weight reductions of 7%, 10%, and 12%, respectively. Subsequently, FLAC3D was used for tensile performance analysis, while coupled PFC3D–FLAC3D was employed for interfacial friction performance analysis. In FLAC3D, numerical simulations demonstrated that the topologically optimized geogrid outperformed conventional ones in both tensile resistance and strain distribution. Consequently, conventional biaxial and triaxial geogrids, along with their topologically optimized versions, were chosen for further analysis. Pull-out interface simulations of these geogrids were conducted using the coupled discrete element–finite difference method (PFC3D–FLAC3D) to investigate the influence of geogrid aperture shape and aperture ratio on the soil–geogrid interface. The results indicate that the reinforcement efficiency of the topologically optimized biaxial and triaxial geogrids was 10% and 8% higher, respectively, than that of the conventional geogrids. Taking the biaxial geogrid as an example, a comprehensive comparison of performance parameters between the conventional and topology-optimized versions revealed that the optimized design achieved a 10% reduction in weight. Simultaneously, it reduced stress concentration at critical locations by approximately 60% and increased the interface pull-out resistance by 20%. These findings demonstrate that the new topologically optimized geogrid exhibits significant potential for further promotion and application in practical engineering.