Kinematic simulation in the aircraft landing gear design and optimization process

Purpose This study aims to investigate the application of kinematic simulations and advanced engineering tools in the design and optimization of aircraft landing gear systems. Focusing on the AT-5 gear retraction/extension system, the research aims to enhance system performance, reliability and safety while addressing design challenges using modern Computer-Aided Design (CAD) and Computer-Aided Engineering (CAE) tools. Design/methodology/approach This study uses Siemens NX Motion software to conduct kinematic simulations, enabling an in-depth analysis of the mechanical behaviour of the landing gear system during extension and retraction. The redesign process included the selection of a new actuator and the development of a lever compatible with the updated actuator. Advanced CAD tools were used to model the components, followed by kinematic studies to assess movement and interactions. Structural integrity was validated through Finite Element Method analyses, ensuring the redesigned components met operational demands while optimizing weight and strength. Findings The kinematic simulations provided critical insights into the dynamics of the redesigned landing gear system, identifying and addressing potential issues during motion analysis. Strength testing confirmed that the new lever design could withstand operational loads without compromising performance or safety. In addition, the integration of CAD/CAM/CAE technologies facilitated a streamlined design and testing process, resulting in an optimized system with improved performance and reduced weight. Originality/value This research highlights the transformative role of CAD and CAE systems in the iterative design and analysis of aircraft landing gear systems. By combining kinematic simulations with structural testing, this study demonstrates a comprehensive approach to system optimization that enhances safety, functionality and efficiency, providing valuable insights for aerospace engineering applications. The improvements were achieved by reducing the overall mass of the system, which contributes to better performance and lower operational loads, as well as by conducting detailed kinematic analyses. These analyses verified the correct operation of the mechanism, ensuring smooth extension and retraction, preventing potential collisions or excessive stresses and confirming the reliability of the system under various operational conditions.