Topology optimisation of a wing box rib using Ansys

The selection of material and design of components are two fundamental topics in the industry for producing sustainable and competitive products. To fulfil the safety, strength and endurance requirements of a component, design tools such as topology and shape optimisation can be utilised during the early stages of the design process. The topology and shape optimisation are sub-fields within structural optimisation. This paper examines the current state of topology optimisation technology and investigates how topology optimisation can be utilised in the aerospace industry. The objective is to minimise the overall weight of an aircraft and increase fuel efficiency, thereby reducing the operating cost and greenhouse gas emissions. This is achieved by exploring the problem of minimizing the mass of an aircraft wing box rib structure without compromising its structural integrity. The optimisation is performed using Ansys Workbench. The results obtained are then manually interpreted to ensure that it conforms to manufacturing constraints. Manual design modifications were required to ensure that the design was one continuous part and that the optimized design could be manufactured easily. A weight saving of about 40% compared to the baseline rib design is achieved with only 10% increase in max stress, which is well within the acceptable limits, i.e.; almost 100 times lower than the yield strength of the material used.

Keywords:

Generative design , topology optimisation , weigh reduction , 3D printing.