CFD Coupled Structural Topology Optimization forAircraft Wings

In aviation, weight is crucial for aircraft performance and payload capacity. Traditional design methods, which rely on trial and error, aim to create lightweight and strong structures but can be time-consuming. Topology optimization, a mathematical technique, speeds up finding the optimal material distribution within a given shape under specific loads and conditions. This study employed ANSYS's CFD and Structural Optimization modules for the topology optimization of a NACA 0012 airfoilwing section under various conditions. The CFD module provided aerodynamic loads to the structural topology optimization module. The study analyzed both 2D and 3D geometries under different conditions, including single-point and multi-point optimizations for 2D sections with varying angles of attack, which provided useful comparisons. For the 3D test case, CFD analysis and topology optimization were performed on a rectangular wing at an inflow speed of 0.5 Mach and a 0⁰ angle of attack. Such combined structural and flow analysis is rare in the literature. This research provides newinsights, highlighting the sensitivity of topology optimization to boundary conditions and computational meshes. Despite challenges from complex geometries, this approach is expected to grow in popularity, especially with advanced production methods like 3D printing and additive manufacturing