Indiana University-Purdue University Indianapolis (IUPUI) / In a multifidelity structural design process, depending on the required analysis, different levels of structural models are needed. Within the aerospace design, analysis and optimization community, there is an increasing demand for automatic generation of parametric feature tree (build recipe) attributed multidisciplinary models. Currently, this is mainly done by creating separate models for different disciplines such as mid-surface model for aeroelasticity, outer-mold line for aerodynamics and CFD, and built-up element model for structural analysis. Since all of these models are built independently, any changes in design parameters require updates on all the models which is inefficient, time-consuming and prone to deficiencies. In this research, Engineering Sketch Pad (ESP) is used to create attribution and maintain consistency between structural models with different fidelity levels. It provides the user with the ability to interact with a configuration by building and/or modifying the design parameters and feature tree that define the configuration. ESP is based an open-source constructive solid modeler, named OpenCSM, which is built upon the OpenCASCADE geometry kernel and the EGADS geometry generation system. The use of OpenCSM as part of the AFRL’s CAPS project on Computational Aircraft Prototype Syntheses for automatic commercial and fighter jet models is demonstrated. The rapid generation of parametric aircraft structural models proposed and developed in this work will benefit the aerospace industry with coming up with efficient, fast and robust multidisciplinary design standardization of aircraft structures. Metallic aircraft wings are usually not optimized to their fullest potential due to shortage of development time. With roughly \$1000 worth of potential fuel savings per pound of weight reduction over the operational life of an aircraft, airlines are trying to minimize the weight of aircraft structures. A stiffness based strategy is used to map the nodal data of the lower-order fidelity structural models onto the higher-order ones. A simple multi-fidelity analysis process for a parametric wing is used to demonstrate the advantage of the approach. The loads on the wing are applied from a stick model as is done in the industry. C program is created to connect the parametric design software ESP, analysis software Nastran, load file and design configuration file in CSV format. This problem gets compounded when it comes to optimization of composite wings. In this study, a multi-level optimization strategy to optimize the weight of a composite transport aircraft wing is proposed. The part is assumed to initially have some arbitrary number of composite super plies. Super plies are a concept consisting of a set of plies all arranged in the same direction. The thickness and orientation angles of the super plies are optimized. Then, each ply undergoes topometry optimization to obtain the areas of each super ply taking the least load so that it could be cut and removed. Each of the super plies are then optimized for the thickness and orientation angles of the sub plies. The work presented on this paper is part of a project done for Air Force Research Laboratory (AFRL) connecting the parametric geometry modeler (ESP) with the finite element solver (Nastran).

This dissertation investigates the advantages of using curvilinear spars and ribs, termed SpaRibs, to design supersonic aircraft wing-box in comparison to the use of classic design concepts that employ straight spars and ribs. The intent is to achieve a more efficient load-bearing mechanism and to passively control aeorelastic behavior of the structure under the flight loads. The use of SpaRibs broadens the design space and allows for the natural frequencies and natural mode shape tailoring. The SpaRibs concept is implemented in a new MATLAB-based optimization framework referred to as EBF3SSWingOpt. This framework interfaces different analysis software to perform the tasks required. VisualDOC is used as optimizer; the generation of the SpaRibs geometry and of the structure Finite Element Model (FEM) is performed by MD.PATRAN; MD.NASTRAN is utilized to compute the weight of the structure, the linear static stress analysis and the linear buckling analysis required for the calculation of the response functions. EBF3SSWingOpt optimization scheme performs both the sizing and the shaping of the internal structural elements. Two methods are compared while optimizing the wing-box; a One-Step method in which sizing and topology optimization are carried out simultaneously and a Two-Step method, in which the sizing and topology optimization are carried out separately but in an iterative way. The optimization problem statements for the One-Step and the Two-Step methodologies are presented. Three methods to define the shape of the SpaRibs parametrically are described: (1) the Bounding Box and Base Curves method defines the shape of the SpaRibs based on the shape of two curves called Base Curves which are positioned into the Bounding Box, a rectangular region defined on the plane z=0 and containing the projection of the wing plan-form onto the same plane; (2) the Linked Shape method defines the shape of a set of SpaRibs in a one by one square domain of the natural space. The set of curves is subsequently transformed in the physical space for creating the wing structure geometry layout. The shape of each curve of each set is unique however, mathematical relations link their curvature in an effort to reduce the number of design variables; and (3) the Independent Shape parameterization is similar to the Linked Shape parameterization however, the shape of each curve is unique. The framework and parameterization methods described are applied to optimize different types of wing structures. Following results are presented and discussed: (1) a rectangular wing-box subjected to a chord-wise linearly varying load, optimized using SpaRibs parameterized with Bounding-Box and Base Curves method; (2) a rectangular wing-box subjected to a chord-wise linearly varying load, optimized using SpaRibs parameterized with Linked Shape method; (3) a generic fighter wing subjected to uniform distributed pressure load, optimized using SpaRibs parameterized with Bounding-Box and Base Curves method; (4) a general business jet wing subjected to pull-up maneuver loads computed using ZESt (ZONA Technology Inc. Steady Euler equations solver), optimized using SpaRibs parameterized with Independent Shape method; (5) a preliminary application of the Linked Shape parameterization to place SpaRibs into a high speed commercial transport aircraft wing-box characterized by high geometry layout complexity; and (6) an optimization of panels subjected to axial and shear loads using curvilinear stiffeners and grids of curvilinear stiffeners. The results for the optimization of the rectangular wing-box show 36.8% weight reduction from the baseline, when the Bounding Box and Base Curves parameterization is applied and the Two-Step framework is implemented. For the same structure the weight reduction amounts to 46.7% when the Linked Shape parameterization and the Two-Step framework are used. Similar results are obtained for the generic fighter wing-box structure. In this case, the weight saving is about 20%. Bounding Box and Base Curves parameterization and Two-Step framework are used. Finally, the weight reduction for the general business jet wing-box structure amounts to 17% of the baseline weight. In this case, the computation is carried out using the Independent Shape parameterization and the Two-Step framework. In general, the Two-Step optimization framework finds better optimal structure configurations as compared to the One-Step optimization framework. However, the computational time required to find to optimum with the Two-Step optimization is larger when a small number of particles are used in the particle swarm optimization method. For larger number of particles, the computational time for the two methods is comparable. Finally for very large number of particles the Two-Step optimization requires less computational time. It is also important to notice how the Two-Step framework consistently leads to a better optimum than the One-Step framework, for the same number of particles. / Ph. D.

A global/local framework for multidisciplinary optimization of generalized aircraft wing structure has been developed. The concept of curvilinear stiffening members (spars, ribs and stiffeners) has been applied in the optimization of a wing structure. A global wing optimization framework EBF3WingOpt, which integrates the static aeroelastic, flutter and buckling analysis, has been implemented for exploiting the optimal design at the wing level. The wing internal structure is optimized using curvilinear spars and ribs (SpaRibs). A two-step optimization approach, which consists of topology optimization with shape design variables and size optimization with thickness design variables, is implemented in EBF3WingOpt. A local panel optimization EBF3PanelOpt, which includes stress and buckling evaluation criteria, is performed to optimize the local panels bordered by spars and ribs for further structural weight saving. The local panel model is extracted from the global finite element model. The boundary conditions are defined on the edges of local panels using the displacement fields obtained from the global model analysis. The local panels are optimized to satisfy stress and buckling constraints. Stiffened panel with curvilinear stiffeners is implemented in EBF3PanelOpt to improve the buckling resistance of the local panels. The optimization of stiffened panels has been studied and integrated in the local panel optimization. EBF3WingOpt has been applied for the optimization of the wing structure of the Boeing N+2 supersonic transport wing and NASA common research model (CRM). The optimization results have shown the advantage of curvilinear spars and ribs concept. The local panel optimization EBF3PanelOpt is performed for the NASA CRM wing. The global-local optimization framework EBF3GLWingOpt, which incorporates global wing optimization module EBF3WingOpt and local panel optimization module EBF3PanelOpt, is developed using MATLAB and Python programming to integrate several commercial software: MSC.PATRAN for pre and post processing, MSC.NASTRAN for finite element analysis. An approximate optimization method is developed for the stiffened panel optimization so as to reduce the computational cost. The integrated global-local optimization approach has been applied to subsonic NASA common research model (CRM) wing which proves the methodology's application scaling with medium fidelity FEM analysis. Both the global wing design variables and local panel design variables are optimized to minimize the wing weight at an acceptable computational cost. / Ph. D.

This master’s thesis is focused on optimization of rear wing of sport car by using open-source software. The optimization of 2D profile of the rear wing is present in this thesis. Python environment was chosen for optimization and evolutionary algorithm was is used as optimization function. This algorithm is further connected to Xfoil software, which is computing aerodynamic characteristic. The ratio of the lift and drag coefficients (C_L/C_D) is chosen as parameter which considers the aerodynamic efficiency. The CFD computation of flowing around the whole car is provided in open-source software OpenFOAM. . The profile optimization results to approximately 7.9 % raise of the parameter C_L/C_D, in the same wing stability. The main benefit of this work is to use open-source software for the optimization and CFD analysis, which in future might save company’s resources by not buying expensive commercial software licenses.