Topology Optimization Results Spaceframe Interpreter for the Design of Lightweight Aircraft Structures
Jack Studnicka
Advisors: David Myszka, Ph.D & Andrew Murray, Ph.D
Department of Mechanical & Aerospace Engineering
Objective: To create a program that interprets the results of commercial topology optimization software and creates a model of a welded frame that is both easily manufacturable and reduces designer subjectivity.
Motivation: Frames used in the aerospace and automotive industry must be rigid and lightweight. Topology optimization (TO) refines a designated design space subjected to a series of loads and restraints, numerically producing a structurally optimized solid part. These shapes are optimized for stiffness with respect to weight, often creating results that are difficult to fabricate using traditional manufacturing methods. TORSI allows these designs to be manufactured using simple methods and removes human bias from the design process, providing a more repeatable result.
The topology optimization interpreter was used on the empennage of a concept tactical aircraft.
1) Cubic Mesher: Converts the variable density tetrahedral elements of the TO results into a binary cubic voxel mesh.
2) Frame Extractor: Image processing techniques are used to convert the cubic mesh into a single-voxel skeleton.
TO Results
Cubic Mesh and Skeleton
Junctions are then identified and clustered by proximity. Members are mapped by tracing paths between junctions along the skeleton.
3) Section Sizer: Minimizes the diameter of the members, and therefore structure weight, while retaining the stiffness of the TO results.
Extracted and Sized Frame using Symmetry
4) Part Modeler: Automatically creates a solid model of the spaceframe within a CAD environment.
Part Modeler
Commercial TO software uses finite element techniques to eliminate elements in a design space that least contribute to the rigidity of the structure.
Processes within TORSI
Topology Optimization on Aircraft