OptiFee

Layout Topology Optimization of Unconventionally Stiffened FRP Structures under Consideration of Manufacturability Criteria

In the topology optimization of stiffened lightweight structures, such as an aircraft fuselage, individual stiffening layouts are evaluated with regard to their mass and manufacturing costs. Detailed structural data is required as a basis for this evaluation. However, particularly for unconventional topologies that deviate from a conventional stringer–frame design, such data is not available without considerable computational effort. In addition, unconventional topologies lead to greater limitations with respect to manufacturability and pose challenges in cost determination. Unconventional stiffening topologies promise advantages in terms of mass, at least when used partially, although these advantages may need to be balanced against potential cost disadvantages.

The OptiFee project follows the research hypothesis that unconventionally stiffened structures can be evaluated with regard to mass, manufacturing costs, and manufacturability even without a detailed structural design, thereby enabling the use of layout topology optimization for the first time in the conceptual design phase. Derived from this, the main objective of the project is the development and investigation of a two-stage, integrated method for evaluating unconventional stiffening topologies with respect to their mass and manufacturing costs while taking manufacturability criteria into account. For this purpose, structures made of carbon-fiber-reinforced plastic (CFRP) will be considered. Due to the currently very high manufacturing costs in this field, the optimization of structures with regard to mass and costs is particularly relevant. An aircraft fuselage structure will serve as an application example. The expected gain in knowledge lies in understanding the relationships and interactions between non-detailed stiffening layouts in the early conceptual design phase and their structural mass, manufacturing costs, and manufacturability.