AOC 2012

Seung-Hyun Jeong, Jae-Chung Heo

Innovation Intelligence
August 6, 2012

Optimization of Upper Torsion Link in Landing Gear System

August 6, 2012

Innovation

Intelligence

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Contents
Background Design Optimization Problem Analysis Model Design Optimization Conclusions

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Background
Failure of Landing Gear System

Airbus A320 in 2005

Boeing 747

Design Requirements

1. The torsion links in the landing gear system should be safe in braking and turning generate high stresses 2. Mass of the torsion link should be minimized

Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Design Optimization Problem

Optimization Problem Formulation
Minimize subject to where Mass of the torsion link

e ,i * ,

e 1,

, NE , i 1,

, NL

NE : number of elements in design domain NL : number of loading cases

e,i : nominal element stress (von Mises stress) * : allowable stress, 450 MPa

Design Domain

Design domain of torsion link (blue color) Non-design domain of torsion link (red color)

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Analysis Model
Full FE Model View Detailed Description
Torsion Link - Solid Element

Drag Strut (titanium)

Outer Cylinder - Thinwalled Tube Beam - Dia: 330 mm - Thickness: 10mm Drag Strut - Solid Circle - Dia: 130 mm Side Strut - Solid Circle - Dia: 130 mm Connection - Rigid Body Element

Side Strut (titanium)

Outer Cylinder (steel)

Torsion Link (titanium)

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Analysis Model
Analysis at an Initial Design
Loading Condition Displacement Stress

Load Case 1 Y-directional Force

Load Case 2

X-directional Moment

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Design Optimization
Topology Optimization Considering Manufacturing

Minimize Mass subject to e ,i *

1.20E+03 1.00E+03 8.00E+02 6.00E+02 4.00E+02 2.00E+02 0.00E+00 250 350 Allowable Stress Value (MPa)

Optimized Stress Value (MPa)

0.4 0.3

Volume Fraction

0.5

Stress limit

0.2

0.1
0 450

Optimized Volume Fraction Max. Stress at Load Case 1 Max. Stress at Load Case 2

Select this as initial layout for shape optimization

0.5 0.45 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0

Optimized Stress Value (MPa)

Volume Fraction

8.00E+02 6.00E+02

Volume Fraction Max. Stress at Load Case 1 Max. Stress at Load Case 2

Minimize Wcomp subject to VF VF

*

Stress limit
4.00E+02 2.00E+02 0.00E+00 0.4 0.3 Volume Fraction 0.2

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Design Optimization
Topology Optimization CAD extraction Free Shape Optimization

Hole radius: 15mm

Max. shape change: 4.694mm

Optimized radius: 20mm

Detail View of Optimized Design

y x

z x
y

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Conclusions
Design Optimization Results

7.00E+02 Stress Value (MPa) 6.00E+02 5.00E+02 4.00E+02 3.00E+02

Stress limit

3.50E+07 2.50E+07 2.00E+07 1.50E+07 Volume (mm3) 3.00E+07 Volume Fraction Max. Stress at Load Case 1 Max. Stress at Load Case 2

2.00E+02 1.00E+02 0.00E+00

Initial Optimized

1.00E+07 5.00E+06 0.00E+00

Volume is reduced by 46.30%. (3.10e7 mm3 1.66e7mm3) All stress constraints are satisfied. Max. stress for the load case 1 is 449.8 MPa. (active constraint) Max. stress for the load case 2 is 222.0 MPa.