A Topology Optimization Methodology With Vibration Constraint for an Aerospace Bracket Design

Abstract The most important need in the aviation industry is the realization of high-strength and lightweight designs. For this reason, topology optimization methods have become widespread recently. Besides, meeting the natural frequency requirements is one of the important design elements. However, topology optimization with stiffness maximization requires a static finite element analysis evaluation while the natural frequency calculation requires a modal analysis evaluation. Using these two different analysis procedures at the same time in the topology optimization process, on the other hand, is a challenging task. To address this challenge, a topology optimization methodology that accounts for the natural frequency constraint in a compliance minimization process is presented in this study. Since the commercial software can either minimize compliance or minimize the vibration frequency at one time, using these two different analysis procedures at the same time together stands out as an innovative aspect of this study. The applicability of the developed methodology is shown for two bracket designs; namely, the so-called GE bracket and a real-world satellite bracket with natural frequency and mass constraints. The prototypes of the designs are fabricated using the additive manufacturing technique.