Strategy for Optimal Configuration Design of Existing Structures by Topology and Shape Optimization Tools

Authors: Waqas Saleem, Fan Yuqing

Abstract:

A strategy is implemented to find the improved configuration design of an existing aircraft structure by executing topology and shape optimizations. Structural analysis of the Initial Design Space is performed in ANSYS under the loads pertinent to operating and ground conditions. By using the FEA results and data, an initial optimized layout configuration is attained by exploiting nonparametric topology optimization in TOSCA software. Topological optimized surfaces are then smoothened and imported in ANSYS to develop the geometrical features. Nodes at the critical locations of resulting voids are selected for sketching rough profiles. Rough profiles are further refined and CAD feasible geometric features are generated. The modified model is then analyzed under the same loadings and constraints as defined for topology optimization. Shape at the peak stress concentration areas are further optimized by exploiting the shape optimization in TOSCA.shape module. The harmonized stressed model with the modified surfaces is then imported in CATIA to develop the final design.

Keywords: Structural optimization, Topology optimization, Shape optimization, Tail fin

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1080666

References:

[1] Y. Panos Papalambros, J. Douglass Wilde, "Principles of optimal design", second edition, Cambridge University press, 2000.
[2] Hans A Eschenauer, Niels Olhoff, "Topology optimization of continuum structures: A review", ASME, Appl Mech Rev Vol 54, No 4, 2001
[3] Kazuhiro Saitou1, Kazuhiro Izui, Shinji Nishiwaki, Panos Papalambros, "A survey of structural optimization in mechanical product development" J. Comput. Inf. Sci. Eng, September 2005 Volume 5, Issue 3, 214
[4] M.P Bendsoe , O. Sigmund, "Material interpolation schemes in topology optimization". Archive of Applied Mechanics, 1999, 69(9/10): 635-654.
[5] M. P. Bendsoe and N. Kikuchi, "Generating optimal topologies in structural design using a homogenization method", Comp. Meths. Appl. Mech. Engrg, 1988, 71, pp 197-224.
[6] Mlejnek H P, Schirrmacher R, "An engineering approach to optimal material distribution and shape finding", Comput Methods Appl Mech Eng 106:1-26, 1993
[7] Jochem Zowe, Michal Kocvara , Martin P. Bendsoe, "Free material optimization via mathematical programming", Mathematical programming, 79, 445-466, 1997
[8] M.P Bendsoe , O. Sigmund, "Material interpolation schemes in topology optimization", Archive of Applied Mechanics 69 (1999) 635-654. Springer-Verlag, 1999
[9] M. Zhou , R. Fleury ,Y.K. Shyy et al, "Progress in topology optimization with manufacturing constraints", AIAA Paper 2002-5614, 2002.
[10] Lothar Harzheim, Gerhard Graf. "A review of optimization of cast parts using topology optimization II", Structural and Multidisciplinary Optimization, 2006, 31(6): 388-399.
[11] Zuo Kong-tian, Chen Li-ping, Zhang Yun-qing, et al. "Manufacturingand machining-based topology optimization", International Journal of Advanced Manufacturing Technology, 2006, 27(5/6): 531-536.
[12] Juan Pablo Leiva, Brian C Watson, Iku Kosaka "An analytical directional growth topology parameterization to enforce manufacturing requirements", AIAA Paper 2004-1645, 2004.
[13] Altair OptiStruct tutorials. www.kxcad.net/, Altair/HyperWorks/ostutorials/optistruct_tutorial.htm.
[14] TOSCA 5.0 user manual. http://download.caenet.cn/ DownInfo6274.html.
[15] O. Sigmund, "Topology optimization from airplanes to nanooptics. In bridging from technology to society", Technical University of Denmark, Lyngby, 2004, pp. 40-51.
[16] Lars Krog, Alastair Tucker, Gerrit Rollema "Application of topology, sizing and shape optimization methods to optimal design of aircraft components"
[17] Krog L, Tucker A. "Topology optimization of aircraft wing box ribs", AIAA Paper 2004-4481, 2004.
[18] Schuhmacher Gerd, Stettner Martin, Zotemantel Rainer, et al. "Optimization assisted structural design of a new military transport aircraft" AIAA Paper 2004-4641, 2004.
[19] Taylor M, Jason E Thomas, Nicholas G. Mackaron, "Detail part optimization on the F-35 joint strike fighter", AIAA Paper 2006-1868, 2006.
[20] Nima Bakhtiary, "A new approach for sizing, shape and topology optimization", SAE international congress and exposition, Detroit, Michigan USA, 1996
[21] Walter Huber, Martin Fischer, Gerald Himmler, "Stress Reduction in an Interstage Air Seal using TOSCA (MSC.Construct) for increasing the LCF Fatigue Life", MSC.Software virtual product development Conference, June 2003, Bad Neuenahr (Germany)
[22] Baud RV, "Fillet profiles for constant stress" Prod Eng 5(4):133- 134
[23] H. Neuber H, Kerbspannungslehre, "Grundlagen f¨ur genaue Festigkeitsberechnung", 2nd edn, Springer, Berlin Heidelberg New York
[24] O.C Zienkiewicz , J.S Campbell JS, "Shape optimization and sequential linear programming". In: Gallagher RH, Zienkiewicz OC (eds) Optimum structural design: theory and applications. Wiley, London, pp. 109-126
[25] E Schnack, "An optimization procedure for stress concentrations by the finite element technique", Int J Numer Math Eng 14:115- 124
[26] Y. Ding, "Shape optimization of structures: a literature survey" Comput Struct 24:985-1004
[27] R.T Haftka, R.V Grandhi, "Structural shape optimizationÔÇöa survey", Comput Methods Appl Mech Eng 57:517-522
[28] N. Kikuchi, Y. K Chung , T. Torigaki, J.E Taylor, Adaptive finite element methods for shape optimization of linearly elastic structures. Comput Methods Appl Mech Eng 57:67-89
[29] Sauter J (1991) CAOS oder die Suche nach der optimalen Bauteilform durch eine effiziente Gestaltoptimierungsstrategie. XX. Internationaler Finite Elemente Kongress, Baden-Baden, November 1991
[30] P. Pedersen, "On optimal shape in materials and structures", Struct Multidisc Optim 19:169-182
[31] S. Chen, D.A Tortorelli, "Three-dimensional shape optimization with variational geometry", Struct Optim 13:81-94
[32] T. Lindby , Santos, "2-D and 3-D shape optimization using mesh velocities to integrate analytical sensitivities with associative CAD", Struct Optim 13:213-222
[33] S.D Rajan, Sizing, shape and topology design optimization of trusses using genetic algorithm, ASCE J Struct Eng 121:1480-1487
[34] M. M Atiqullah, S. S Rao, "Parallel processing in optimal structural design using simulated annealing", AIAA J 33:2386-2392
[35] W. J Stroud, C. B Dexter, M. Stein, "Automated preliminary design of simplified wing structures to satisfy strength and flutter requirements", NASA TN D-6534.
[36] K. Dems, "Multiparameter Shape Optimization of Elastic Bars in Torsion", Intl Jour for Numerical Methods in Engineering, Vo1.15, pp. 1517-1539.
[37] R. J Yang, K.K Choi, "Accuracy of Finite Element Based Shape Design Sensity Analysis", Journal of Structural Mechanics, ASCE
[38] V. Braibant, C. Fleury, P. Beckers, "Shape optimal design. an approach matching cad and optimization concepts", Report SA-109, Aerospace Laboratory o f the University of Liege, Belgium, 1983
[39] Nitsopoulos, Ioannis, Lauber, "Overview on optimization methods", journal of applied mechanics ASME JULY 2006, Vol. 73 / 565