In aerospace industry, optimizing designs has become inevitable in terms of weight and performance requirements. Topology optimization is the most suitable optimization type for use in the conceptual design phase. Even though academic topology optimization algorithms have a modular structure (open to development), they are often useable for a regular design domain. Alternatively, commercial topology optimization software products, on the other hand, are very useful in terms of their solution speed, accuracy, and ability to handle complex or irregular design domains. However, the user is restricted with the optimization algorithms available in the software, and these software do not usually have a modular structure. In this study, a modular topology optimization framework that combines useful features of the academic codes (e.g., modularity) and the commercial software tools (e.g., capability of easily handling complex design domains) is developed. The developed framework is tested on two popular academic topology optimization problems, followed by aerospace bracket design problem. It is observed that the proposed framework usually provides lower objective function values and converges to the optimum result in fewer iterations than the Altair Optistruct topology optimization software.
The most important need in the aviation industry is the realization of high-strength and lightweight designs. For this reason, topology optimization methods have become widespread recently. Besides, meeting the natural frequency requirements is one of the important design elements. However, topology optimization with stiffness maximization requires a static finite element analysis evaluation while the natural frequency calculation requires a modal analysis evaluation. Using these two different analysis procedures at the same time in the topology optimization process, on the other hand, is a challenging task. To address this challenge, a topology optimization methodology that accounts for the natural frequency constraint in a compliance minimization process is presented in this study. Since the commercial software can either minimize compliance or minimize the vibration frequency at one time, using these two different analysis procedures at the same time together stands out as an innovative aspect of this study. The applicability of the developed methodology is shown for two bracket designs; namely, the so-called GE bracket and a real-world satellite bracket with natural frequency and mass constraints. The prototypes of the designs are fabricated using the additive manufacturing technique.
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