This paper considers the application of conventional energy based topology optimization methods for design of aircraft wing box ribs. Compared to standard topology optimization work undertaken at Airbus, the topology optimization of wing box ribs posed several additional challenges, mainly due to the wing box ribs being embedded in a redundant wing box structure. Several approaches to solving this problem have been investigated and are being reported as part of this paper, including a global analysis/optimization approach and two local analysis/optimization approaches. The paper also deals with both the selection of a suitable objective/constraint function formulation for topology optimization and selection of a suitable formulation for handling multiple load cases in topology optimization, but does not deal with any detailed sizing optimization of topology optimized designs.

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-Structure optimization at airframe level is mainly focused on sizing design variables detailing the thin-walled properties of aircraft structures. Typical design variables are cross sectional dimensions for 1D and 2D elements with an additional complexity brought by composite materials with their directional and multi-layer aspects. Even if the scope of these design variables is clear and well understood, the vision of the structure behaviour is multi-criteria and encompasses various fidelity levels. Its design requires several stages from the future project to the detailed definition of structural parts using various analysis tools from different disciplines. These several stages require adequate structural optimization processes to offer the best response with the right level of details to answer questions being sought at each maturity level of the design. A review of methods & tools developed and applied at AIRBUS to deliver automated sizing for aircraft structures along their development will be presented. Ways forward and major stakes for the future will be discussed.

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