Leveraging Geometry Optimization Tools to Reduce Component Weight, Development Cost, and Design Schedule

Structural optimization tools such as OptiStruct enable design and stress engineers to visualize the most efficient load paths for a prescribed design space within the context of multiple load cases and boundary conditions. The main rotor gearbox (MRGB) team from the Sikorsky Boeing Joint Multi Role (JMR) SB>1 DEFIANT™ Aircraft leveraged these capabilities to streamline the development of complex gearbox housings. The benefits included more effective initial designs, reduced design / stress iterations and cycle time, and improved part weight performance. Based on experience from the JMR program, the practical application of optimization tools is discussed with a summary of advantages and limitations. In addition, several example applications from the SB>1 DEFIANT™ Aircraft MRGB are discussed in detail with an account of benefits observed and lessons learned.