Weight reduction with topology optimization for aircraft wings

In aviation, weight significantly impacts aircraft performance and payload capacity. Design processes focuses on achieving lighter yet robust structures, albeit time-consuming to attain ideal geometry. Topology optimization, considering set conditions and loads, expedites finding optimal material distribution within desired geometry. In this thesis study, topology optimization was performed using the Structural Optimization module of ANSYS software for a wing section with a NACA 0012 airfoil and a wing with a 4 m wingspan. Geometries were modeled using 3D modeling. Then, Computational Fluid Dynamics (CFD) analyses for the wing section at steady state and sea level with a speed of 100 m/s, were performed with Fluent under incompressible viscous and turbulent flow conditions. Solutions were made at seven different attack angles: -15⁰, -10⁰, -5⁰, 0⁰, 5⁰, 10⁰, 15⁰. Two different situations were designed for optimizations; First, a rigid spar was positioned in the middle of the wing sections. In the other scenario, two vertical ribs are positioned at 0.25 and 0.5 positions of the chord length. CFD analysis solutions at all angles of attack were transferred separately to the sections in these two scenarios and topology optimizations were performed for the volume ratios were 20% and 10%, respectively. Then, multi-point topology optimization was performed for these two scenarios simultaneously using seven different angles of attack. This was one aspect that differentiated this thesis study from other studies. The simultaneous use of seven different angle of attack solutions in multi-point optimization has not been found in the literature research. Additionally, there are few studies using aerodynamic load calculated with CFD solution for wing geometry. After the wing section optimization was completed, CFD analysis of a wing with a 4 m wingspan was performed at a flow rate of 0.5 Mach, steady state and 0⁰ angle of attack. The results for the optimum geometry were examined by applying the 10% volume ratio condition for the fully loaded wing. The research highlighted the sensitivity of topology optimization to boundary conditions and meshes, emphasizing the need for precise problem definition. Varied factors significantly impact solutions, allowing for the generation of original outcomes. Consequently, topology optimization proves highly effective in engineering designs. Its capability to yield intricate, optimal results foresees increased utilization, especially with advancing production technologies.