21 Realization of Nonparametric Structural Optimization in Design of Aircraft Components

The Inadequacies of classical design process in developing load compatible-lightweight components have compelled the designers to exploit CAE (computer aided engineering) structural optimization tools effectively early at design stage. Currently, the contemporary design process has entered to a realm where CAE based optimization; simulations and analysis are indispensable for designing the optimal configurations of novel products. In this research, nonparametric three-dimensional structural topology optimization is investigated to find the novel load-compatible configuration design of an operating structure of civil aircraft by exploiting TOSCA and ANSYS software. Analytical load calculations pertinent to the operating and ground conditions are estimated and applied by considering the orientation of structural assembly members and build-in supports offered in the main structure. A smoothened topological optimized model is then imported in CATIA software to extract the CAD viable design. A methodology is also devised to modify the layout of topological optimized voids with splines and fillets, to construct manufacturalbe features and avoid stress concentrations. The resulting novel design is then analyzed and validated against stipulated loads, constraints and other requirements.