A methodology is implemented to find the optimum reduced weight configuration design of an operating structure of a civil aircraft vertical tail fin. FE (finite element) based topology optimization is executed to find the optimum material distribution of initial design space of rib by maximizing the stiffness. Loads pertinent to the operating and ground conditions are estimated and applied, considering the orientation of structural assembly members and built-in supports offered in the main structure. Manufacturing constraints are incorporated into the optimization loop to generate pragmatic and manufacturable design configuration. The topologically optimized configuration is then converted to CAD viable design through data reduction and smoothing by converting to ISO-surfaces. A methodology is also devised to modify the topological optimized voids and material layout precisely with splines and fillets to construct manufacturable features and avoid stress concentrations. The resulting novel design proposal is then analyzed and validated against stipulated loads, constraints and other design needs. Results validate the new design proposal as more reliable, having reduced weight and enhanced structural performance.
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