This thesis discusses a methodology for probabilistic design optimization of aircraft structures subject to a multidisciplinary set of requirements originating from the desire to minimize structural weight while fulfilling the demands for quality, safety, producibility, and affordability. With this design methodology as the framework, a software is developed, which is capable of performing design optimization of metallic built-up beam structures where the material properties, external load, as well as the structural dimensions are treated as probabilistic random variables. The structural and failure analyses are based on analytical and semi-empirical methods whereas the component reliability analysis is based on advanced first-order second moment method. Metrics-based analytical models are used for the manufacturability analysis of individual parts with the total manufacturing cost estimated using models derived from the manufacturing cost / design guide developed by the Battelle¡¯s Columbus Laboratories. The resulting optimization problem is solved using the method of sequential quadratic programming. A wing spar design optimization problem is used as a demonstrative example including a comparison between non-buckling and buckling web design concepts. A sensitivity analysis is performed and the optimization results are used to highlight the tradeoffs among weight, reliability, and manufacturing cost.

In this thesis, the structural design, structural analysis and producibility analysis of an unmanned aerial vehicle wing were performed. Three different wing models, made of different materials, were designed. The wings were aluminum wing model and composite wing models / made of prepreg and wet lay-up. All wings have the same aerodynamic geometry and structural configuration under the same flight conditions. The structural designs of three wings were done by using Unigraphics NX. The finite element modeling of the wings were built by using MSC Patran package program. After the application of the loads on models, structural analyses were performed by MSC Nastran. Finally, the producibility analysis of prepreg wing model was conducted by using FiberSIM package program. The prepreg wing model was selected as optimum design with studies conducted in the study considering weight, producibility, cruise and gust stress and displacement conditions.