EFFICIENT TOPOLOGY OPTIMIZATION AND DESIGN METHODS FOR AN AEROSPACE COMPONENT

Sammanfattning

In Aerospace engineering, Topology Optimization (TO) combined with Additive Manufacturing (AM) presents great potential for reducing weight and improving performance. However, a common challenge is the conversion of topology optimized results, which usually come as mesh-based geometries, into editable precise geometry for further design and manufacturing. This thesis suggests a practical workflow to tackle this challenge by linking TO, post-processing, and structural validation steps into a unified process. In this work, a comparative study of topology optimization software tools including ANSYS, Siemens NX, nTopology, Altair Optistruct and Autodesk Fusion 360 was carried out on criteria such as constraint handling, ANSYS solver integration and output file capability. The study was eventually carried out in ANSYS to examine the topology optimization of a jet engine: Transition Frame (TF) incorporating relevant constraints aimed at maximizing the stiffness. Two Precise geometry conversion methods are assessed: with ANSYS SpaceClaim and nTopology. A custom block was created in the latter to automate geometry smoothing and solid conversion. The final models were exported as editable precise geometry files and validated. This work introduces a structured workflow combining topology optimization, precise geometry conversion, and validation to effectively run TO studies & transform mesh-based TO results. The proposed approach offers a foundation for future refinement and broader application in aerospace design and manufacturing.