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Biomechanics
 Reliability of Multiphysical Systems Set
coordinated by
Abdelkhalak El Hami

Volume 5

Biomechanics

Optimization, Uncertainties and Reliability

Ghias Kharmanda
Abdelkhalak El Hami
First published 2017 in Great Britain and the United States by ISTE Ltd and John Wiley & Sons, Inc.

Apart from any fair dealing for the purposes of research or private study, or criticism or review, as
permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced,
stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers,
or in the case of reprographic reproduction in accordance with the terms and licenses issued by the
CLA. Enquiries concerning reproduction outside these terms should be sent to the publishers at the
undermentioned address:

ISTE Ltd John Wiley & Sons, Inc.

27-37 St George’s Road 111 River Street
London SW19 4EU Hoboken, NJ 07030
UK USA

www.iste.co.uk www.wiley.com

© ISTE Ltd 2017

The rights of Ghias Kharmanda and Abdelkhalak El Hami to be identified as the authors of this work
have been asserted by them in accordance with the Copyright, Designs and Patents Act 1988.

Library of Congress Control Number: 2016952066

British Library Cataloguing-in-Publication Data

A CIP record for this book is available from the British Library
ISBN 978-1-78630-025-6
 Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Chapter 1. Introduction to Structural Optimization . . . . . . . . . . . . . . . . 1

1.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. History of structural optimization . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3. Sizing optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1. Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.2. First works in sizing optimization . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.3. Numerical application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4. Shape optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.1. Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4.2. First works in shape optimization . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.3. Numerical application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5. Topology optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5.1. Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5.2. First works in topology optimization . . . . . . . . . . . . . . . . . . . . . 17
1.5.3. Numerical application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 2. Integration of Structural Optimization

into Biomechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2. Integration of structural optimization into
orthopedic prosthesis design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
vi Biomechanics

2.2.1. Structural optimization of the hip prosthesis . . . . . . . . . . . . . . . . . 24

2.2.2. Sizing optimization of a 3D intervertebral
disk prosthesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3. Integration of structural optimization into
orthodontic prosthesis design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3.1. Sizing optimization of a dental implant . . . . . . . . . . . . . . . . . . . . 47
2.3.2. Shape optimization of a mini-plate . . . . . . . . . . . . . . . . . . . . . . 49
2.4. Advanced integration of structural optimization
into drilling surgery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.4.1. Case of treatment of a crack with a single hole. . . . . . . . . . . . . . . . 53
2.4.2. Case of treatment of a crack with two holes . . . . . . . . . . . . . . . . . 54
2.5. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Chapter 3. Integration of Reliability into

Structural Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2. Literature review of reliability-based optimization . . . . . . . . . . . . . . . . 58
3.3. Comparison between deterministic and
reliability-based optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.3.1. Deterministic optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.3.2. Reliability-based optimization . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.4. Numerical application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.4.1. Description and modeling of the studied problem . . . . . . . . . . . . . . 64
3.4.2. Numerical results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.5. Approaches and strategies for
reliability-based optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.5.1. Mono-level approaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.5.2. Double-level approaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.5.3. Sequential decoupled approaches . . . . . . . . . . . . . . . . . . . . . . . 68
3.6. Two points of view for developments of
reliability-based optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.6.1. Point of view of “Reliability” . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.6.2. Point of view of “Optimization” . . . . . . . . . . . . . . . . . . . . . . . . 70
3.6.3. Method efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.7. Philosophy of integration of the concept of
reliability into structural optimization groups . . . . . . . . . . . . . . . . . . . . . 72
3.8. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Chapter 4. Reliability-based Design

Optimization Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2. Classic method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
 Contents vii

4.2.1. Formulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2.2. Optimality conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2.3. Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2.4. Advantages and disadvantages. . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3. Hybrid method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3.1. Formulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3.2. Optimality conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.3.3. Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3.4. Advantages and disadvantages. . . . . . . . . . . . . . . . . . . . . . . . . 85
4.4. Improved hybrid method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.4.1. Formulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.4.2. Optimality conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.4.3. Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.4.4. Advantages and disadvantages. . . . . . . . . . . . . . . . . . . . . . . . . 90
4.5. Optimum safety factor method . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.5.1. Safety factor concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.5.2. Developments and optimality conditions . . . . . . . . . . . . . . . . . . . 92
4.5.3. Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.5.4. Advantages and disadvantages. . . . . . . . . . . . . . . . . . . . . . . . . 98
4.6. Safest point method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.6.1. Formulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.6.2. Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.6.3. Advantages and disadvantages. . . . . . . . . . . . . . . . . . . . . . . . . 104
4.7. Numerical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.7.1. RBDO of a hook: CM and HM . . . . . . . . . . . . . . . . . . . . . . . . 105
4.7.2. RBDO of a triangular plate: HM & IHM . . . . . . . . . . . . . . . . . . . 107
4.7.3. RBDO of a console beam
(sandwich beam): HM and OSF . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.7.4. RBDO of an aircraft wing: HM & SP . . . . . . . . . . . . . . . . . . . . . 113
4.8. Classification of the methods developed. . . . . . . . . . . . . . . . . . . . . . 115
4.8.1. Numerical methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.8.2. Semi-numerical methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.8.3. Comparison between the numerical- and
semi-numerical methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.9. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Chapter 5. Reliability-based Topology

Optimization Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.2. Formulation and algorithm for the RBTO model . . . . . . . . . . . . . . . . . 122
5.2.1. Formulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
viii Biomechanics

5.2.2. Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

5.2.3. Validation of the RBTO code developed . . . . . . . . . . . . . . . . . . . 125
5.3. Validation of the RBTO model . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.3.1. Analytical validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.3.2. Numerical validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.4. Variability of the reliability index . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.4.1. Example 1: MBB beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.4.2. Example 2: Cantilever beam . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.4.3. Example 3: Cantilever beam with double loads . . . . . . . . . . . . . . . 136
5.4.4. Example 4: Cantilever beam with a transversal hole. . . . . . . . . . . . . 136
5.5. Numerical applications for the RBTO model . . . . . . . . . . . . . . . . . . . 137
5.5.1. Static analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.5.2. Modal analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.5.3. Fatigue analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.6. Two points of view for integration of reliability
into topology optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.6.1. Point of view of “topology” . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.6.2. Point of view of “reliability” . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.6.3. Numerical applications for the two points of view . . . . . . . . . . . . . . 146
5.7. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Chapter 6. Integration of Reliability and

Structural Optimization into Prosthesis Design . . . . . . . . . . . . . . . . . 153
6.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.2. Prosthesis design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
6.3. Integration of topology optimization
into prosthesis design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
6.3.1. Importance of topology optimization
in prosthesis design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.3.2. Place of topology optimization in
the prosthesis design chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.4. Integration of reliability and structural
optimization into hip prosthesis design . . . . . . . . . . . . . . . . . . . . . . . . . 157
6.4.1. Numerical application of the deterministic approach . . . . . . . . . . . . 158
6.4.2. Numerical application of the reliability-based approach . . . . . . . . . . 167
6.5. Integration of reliability and structural
optimization into the design of mini-plate systems
used to treat fractured mandibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
6.5.1. Numerical application of the
deterministic approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
6.5.2. Numerical application of the
reliability-based approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
 Contents ix

6.6. Integration of reliability and structural

optimization into dental implant design. . . . . . . . . . . . . . . . . . . . . . . . . 184
6.6.1. Description and modeling of the problem . . . . . . . . . . . . . . . . . . 184
6.6.2. Numerical results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.7. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Appendix 1. ANSYS Code for Stem Geometry . . . . . . . . . . . . . . . . . . 191

Appendix 2. ANSYS Code for Mini-Plate Geometry . . . . . . . . . . . . . . . 197

Appendix 3. ANSYS Code for Dental Implant Geometry . . . . . . . . . . . . 201

Appendix 4. ANSYS Code for Geometry

of Dental Implant with Bone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
 Preface

The integration of structural optimization into biomechanics is a truly vast

domain. In this book, we first focus on the integration of structural optimization into
the design of orthopedic and orthodontic prostheses, and also into drilling surgery.
Next, we present the integration of reliability and structural optimization into the
design of these prostheses, which may be considered as a novel aspect introduced in
this book. The applications are made in 2D and in 3D, considering the three major
families of structural optimization: sizing-, shape- and topology optimization.

In all domains of structural mechanics, good design of a part is very important for
its strength, its lifetime and its use in service. This is a challenge faced daily in sectors
such as space research, aeronautics, the automobile industry, naval competition, fine
mechanics, precision mechanics or artwork in civil engineering, and so on. To develop
the art of the engineer requires enormous effort to continuously improve the
techniques for designing structures. Optimization is of primary importance in
improving the performance and reducing the weight of aerospace- and automobile
engines, providing substantial energy savings. The development of computer-aided
design (CAD) techniques and optimization strategies is part of this context.

Applying structural optimization is still somewhat complicated in certain

domains. Furthermore, in deterministic structural optimization, all parameters which
are uncertain in nature are described by unfavorable characteristic values, associated
with safety coefficients. The deterministic approach uses a pessimistic margin
determined as a function of the consequences of a probable failure. This approach
often leads to unnecessary oversizing – particularly for sensitive structures.

On the other hand, researchers have developed a different approach which is

better suited to uncertain physical phenomena. In this approach, the structure is
deemed to have failed if the probability of failure is greater than a fixed threshold.
This is known as the “probabilistic approach”. The probabilistic approach is
xii Biomechanics

increasingly widely used in engineering, as evidenced by the different applications

in industry. It is applied to check that the probability is sufficient when the
structure’s geometry is known, or to optimize the sizing of the structure so as to
respect certain fixed objectives, such as a target cost or a required level of
probability.

Furthermore, reliability analysis is an important tool in decision-making for

establishing a maintenance- and inspection plan. In addition, it can be used in the
validation of standards and regulations. To perform reliability analysis, various
methods can be used to effectively and simply find the probability of failure.
Reliability analysis is a strategy used to evaluate the level of reliability without
being able to control the design for a required reliability level. For this, reliability
has become an important tool to be integrated into the process of structural
optimization.

This book also focuses on the necessary tools for the integration of reliability and
structural optimization into biomechanics fields. First, the deterministic strategies of
structural optimization are presented so we can implement them in structural design.
These deterministic strategies are applied in various domains in biomechanics,
including the design of orthopedic and orthodontic prostheses and drilling surgery.
Next, reliability-based approaches pertaining to the integration of reliability into
structural optimization are presented in detail, with mechanical applications. These
reliability-based strategies are also applied in the design of orthopedic and
orthodontic prostheses, taking account of uncertainty in terms of geometry, materials
and load. Finally, system reliability strategies are also taken into account,
considering several failure scenarios.

The book will provide invaluable support to teaching staff and researchers. It is
also intended for engineering students, practising engineers and Masters students.

Acknowledgements

We would like to thank all of those people who have, in some way, great or
small, contributed to the writing of this book – in particular, Sophie Le Cann, a
researcher at the Biomedical Centre (BMC) at Lund University, for her contribution
in terms of biological language. Heartfelt thanks go to our families, to our students,
and to our colleagues for their massive moral support during the writing of this
book.

Ghias KHARMANDA
Abdelkhalak EL-HAMI
October 2016
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