Alternate Detail Part Design and Analysis: Topology, Size, and Shape Optimization of CH-47 Chinook Underfloor Structure

Topology optimization is a finite element solution method used to develop an optimal initial design concept by migrating material mass based on the applied loads, boundary conditions, and practical manufacturing input. The powerful result in using topology optimization is revealing the best possible load path to the end user. The application of this technology in structural design and analysis yields the most efficient, lowest weight, highest stiffness design possible. Weight savings of 15% to 20% are typical using topology optimization technology. A process, using topology optimization, has been successfully demonstrated for a monolithic bulkhead/frame structure in the ramp portion of the Chinook helicopter, which produced a weight savings of 2.40 pounds, a 17% reduction from the traditional monolithic web-frame design. Validation through finite element analysis and test, along with cost and manufacturing data is expected to provide program management with a compelling option for realizing the benefits which this process and tool is capable of providing.