A Configurable B-spline Parameterization Method for Structural Optimization of Wing Boxes

This dissertation presents a synthesis of methods for structural optimization of aircraft wing boxes. The optimization problem considered herein is the minimization of structural weight with respect to component sizes, subject to stress constraints. Different aspects of structural optimization methods representing the current state-of-the-art are discussed, including sequential quadratic programming, sensitivity analysis, parameterization of design variables, constraint handling, and multiple load treatment. Shortcomings of the current techniques are identified and a B-spline parameterization representing the structural sizes is proposed to address them. A new configurable B-spline parameterization method for structural optimization of wing boxes is developed that makes it possible to flexibly explore design spaces. An automatic scheme using different levels of B-spline parameterization configurations is also proposed, along with a constraint aggregation method in order to reduce the computational effort. Numerical results are compared to evaluate the effectiveness of the B-spline approach and the constraint aggregation method. To evaluate the new formulations and explore design spaces, the wing box of an airliner is optimized for the minimum weight subject to stress constraints under multiple load conditions. The new approaches are shown to significantly reduce the computational time required to perform structural optimization and to yield designs that are more realistic than existing methods.Ph