Application of Topology Optimization and Manufacturing Simulations - A new trend in design of Aircraft components

Structural optimization tools and computer simulations have gained the paramount importance in industrial applications as a result of innovative designs, reduced weight and cost effective products. Especially, in aircraft and automobile industries, topology optimization has become an integral part of the product design process. In this paper nonparametric topology optimization has been applied on a commercial aircraft vertical stabilizer component using ANSYS software. Suitable loads and constraints are applied on the initial design space of the component to accommodate for fin gust, rudder deflection, lateral gust, and other loads experienced by an aircraft during actual flight maneuvering. An integrated approach has also been developed to verify the structural performance and to overcome the problem of nonmanufacturable topology optimization results. Post machining distortions are also simulated by using element deactivation technique first by developing an initial residual stress field through Sequential Coupled Field analysis. CATIA is used to convert the optimized FE model into geometry based CAD model and then virtual machining is done. At the end topology assisted design model is compared with the actual part that is being manufactured for the aircraft. It is inferred that topology optimization results in a better and innovative product design with enhanced structural performance and stability.