Topology Optimization of Aircraft Components for Increased Sustainability

The aim of this work is to explore a topology optimization approach for the design of load-bearing aircraft components. The main objective of the approach is to develop a design methodology that reduces the maximum stress in a component for a given applied load and weight constraint. Consequently, the load carrying capacity and fatigue life of the component are maximized, resulting in less downtime and increased sustainability of the aircraft. A representative component geometry has been selected that is a potential candidate for additive manufacturing in order to enable the enhanced design freedom required of topology optimization approaches. Both linear and nonlinear-static finite element analyses are performed to validate the improved performance of the topologically optimized component, as well as contact analyses to demonstrate that the resulting design cannot be further improved without redesigning the complete assembly. The optimization problem is formulated and solved using a bidirectional evolutionary structural optimization method. The method demonstrates large reductions in maximum stress, leading to significant increases in fatigue life, potentially compensating for the degradation in fatigue properties inherent in additively manufactured metallic structures. The added design flexibility of additive manufacturing combined with topology optimization offer the potential for an anywhere, anytime manufacturing capability that would greatly benefit aircraft sustainability.