- Conference Article
- 10.2514/6.2026-0585
Topology Optimization and Detailed Analysis of a Stability Critical Aerospace Application
- Jan 08, 2026
- Jason Action + 3 more +3
A comparative study of linear and non-linear topology optimization was conducted on a UAV bulkhead featuring a stiffened thin web configuration. Both optimization workflows employed Abaqus as the finite element solver coupled with Tosca for topology optimization. The linear optimization converged to a design that removed half of the material from the web design space and satisfied most constraint criteria; however, subsequent full non-linear verification analysis revealed a loss of stability under the applied load cases, rendering the design unsuitable. In contrast, the non-linear optimization also removed half of the material from the web design space while fulfilling all constraint requirements. Non-linear verification analysis of the non-linear optimized result confirmed a robust solution that met the targeted performance objectives. Comparisons of the optimization results indicated that both optimized designs redistributed material to similar regions, yet the linear approach failed to capture critical load path interactions fully. The final non-linear optimized design was reconstructed into a manufacturable part using conventional milling processes. Evaluation of the reconstructed machined part demonstrated compliance with initial cost, performance, and durability benchmarks and achieved a 15 % reduction in total part weight relative to the baseline part.
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