This study applies topology optimization techniques to redesign an existing aircraft installation component, incorporating additive manufacturing constraints. Using ANSYS software, the research optimizes a part currently made of AL7050, comparing it with alternatives in Ti-6Al-4V (Ti64) and AlSi10Mg. The optimization process considers manufacturing and installation constraints while aiming to minimize compliance and reduce mass. Results show significant mass reductions across all materials, with AlSi10Mg achieving the most substantial improvement of 38.20% mass reduction and a minimum safety factor of 1.49. The study demonstrates the practical application of combining topology optimization and additive manufacturing in aerospace component design, highlighting opportunities for improved fuel efficiency and sustainable air transportation systems. The research also addresses challenges in integrating manufacturing constraints and material properties into the optimization process. Future work recommendations include exploring multi-physics optimization approaches and investigating the long-term performance of topology-optimized parts in aerospace applications.
Totuk et al. (Mon,) studied this question.