Topology Optimization Procedure of Aircraft Mechanical Components Based on Computer-Aided Design, Multibody Dynamics, and Finite Element Analysis

In mechanical engineering, the optimization process is time-consuming because of the lack of communication between design, simulation, and analysis software. In the case of single productions or small quantities, this possibility is not taken into account. In the case of serial productions, on the other hand, the optimization of the design time is of paramount importance due to the large amount of money that can be saved. To address these challenges, this investigation proposes a topological optimization procedure for mechanical parts that have complex geometric shapes using the integration of CAD, MBD, and FEA software. The theory of linear elastodynamics is the basic approach used for the integration process carried out in this paper. In particular, the components analyzed in this work belong to the closing system of the ATR 42/72 cargo door. To explain the software integration procedure devised in the paper using SOLIDWORKS, MSC ADAMS, and ANSYS, a slider-crank mechanism is employed first as a demonstrative example. Subsequently, this computational procedure is applied to a flexible component of the latching system of the door whose loading conditions were previously obtained considering the entire opening mechanism modeled as a rigid multibody system. Finally, the topological optimization of the mechanical part is carried out and a consequential reduction in the amount of material to use is performed. The results obtained are considered significant since they led to considerable advantages in the door opening and closing system as well as a reduction of the total weight of the entire airplane.