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The design of continuum structures often presents challenges related to stress concentration, which can cause significant structural damage. To address this issue, the current study presents a new stress minimization method that utilizes the Windowed Evolutionary Structural Optimization (WESO) framework. The method aims to improve algorithm stability by optimizing design variables with an intermediate density. The use of a P‐norm stress aggregation method improves the assessment of global stress levels and enhances computational efficiency. Furthermore, a stable element sensitivity formulation, derived from the adjoint sensitivity analysis of the global stress measure, effectively handles the nonlinear stress behavior. Mesh filtering techniques are utilized to convert sensitivity from elements to nodes, and the structural topological solution is represented using the level set function (LSF) based on element‐node sensitivity. This method addresses the singularity issue commonly found in density‐based optimization methods and facilitates the achievement of smooth topological solutions. Through 2D and 3D benchmark designs, the proposed method's feasibility, stability, and superiority are thoroughly demonstrated. A parametric study is conducted to identify the optimal parameter range for the algorithm, leading to the development of a rational method for parameter selection. The optimized topology, with its smooth boundaries, can guide the design of structures without the need for redesign or post‐processing, helping to drive innovation and development in engineering. [ABSTRACT FROM AUTHOR]

To meet the needs of industrial production, an improved evolution structural optimization (ESO) method with high efficiency is proposed. The optimized design variables with intermediate density were designed using the windowed evolution structural optimization (WESO) method to increase the stability of the algorithm. The efficient calculation method of the element node sensitivity was established, which realizes the establishment of level set functions, smooth topological design of structures and the updating of design variables. The stability of the proposed algorithm was verified by the Zhou–Rozvany problem, two- and three-dimensional (3D) numerical results. The effectiveness and efficiency of the proposed algorithm was further verified by numerical comparison with other topology optimization frameworks. Lastly, the improved windowed ESO method was applied to the initial configuration design of the double-deck bridge structure, which not only provides guidance for its initial design but also demonstrates the applicability of the method in complex structural systems. [ABSTRACT FROM AUTHOR]

To study the design method of openings on the web of an I-beam, three I-beams with different circular holes were designed using the traditional truss mechanism, and the circular holes were reinforced by ring stirrups. A shear test was performed to study the failure modes of the I-beams and efficiency of the ring stirrups. A new method for establishing the truss mechanism was proposed, which used the windowed evolutionary structural optimization method to calculate the topology optimization solution of the I-beam. From the topology optimization results, the strut-and-tie model (STM) was established, which revealed the stress mechanism of the I-beam. Via the STM, the optimal shape and location for the opening of the I-beam under shear load states were presented. The quantity of reinforcing bars, porosity and ultimate load of the I-beam designed by the STM were, respectively, 0.67, 5.5 and 1.2 times those of the experimental model. [ABSTRACT FROM AUTHOR]