Topology Optimization of a Jet Engine Bracket with Structural Integrity Validation in Ansys Mechanical

Categories: Ansys, Engineering files, Finite Element, Optimization

Mohammed Hossain

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Weight Reduction Potential
The analysis demonstrated that significant weight savings (from 2.085 kg to 0.6299 kg) can be achieved using topology optimization without compromising structural performance.
Such reduction highlights the importance of optimization techniques in aerospace applications, where every kilogram of weight directly impacts efficiency.
Structural Integrity Validation
Even after material removal, the optimized bracket withstood the applied loads and boundary conditions within the yield strength of Ti-6Al-4V (903 MPa).
This confirms that topology optimization not only reduces weight but also ensures safety when properly validated.
Material and Design Synergy
The use of titanium alloy (Ti-6Al-4V) proved effective due to its high strength-to-weight ratio, making it well-suited for lightweight aerospace components.
The study reinforced the importance of aligning material selection with design optimization techniques.

About Course

Introduction

Lightweight structural design plays a crucial role in the aerospace industry, where reducing component mass directly contributes to improved fuel efficiency, reduced emissions, and enhanced overall performance. Among the various structural components, the jet engine bracket is a critical part that connects the engine to the airframe and transfers loads during operation. Although the bracket is relatively small in size compared to the entire engine assembly, it experiences significant loads and therefore requires both high strength and minimal weight.

Topology optimization has emerged as an effective approach to achieve lightweight yet structurally sound designs. By redistributing material within a defined design space while satisfying load and boundary conditions, topology optimization provides an optimized geometry that minimizes mass without compromising mechanical performance.

In this study, topology optimization of a jet engine bracket is performed using Ansys Mechanical, with load conditions extracted from published research work to ensure realistic analysis. The optimized geometry is post-processed (cleaned) and subsequently validated through structural analysis under the same loading and boundary conditions. The titanium alloy Ti-6Al-4V (yield strength: 903 MPa) is selected as the material due to its widespread use in aerospace applications, combining high strength with low density. The optimization resulted in a significant weight reduction from 2.085 kg to 0.6299 kg, demonstrating the potential of topology optimization in achieving lightweight designs without compromising structural integrity.

Objectives

The primary objectives of this analysis are:

To perform topology optimization of a jet engine bracket using Ansys Mechanical in order to minimize its mass while retaining structural performance.
To validate the optimized design by performing structural analysis under the same loading and boundary conditions as the baseline bracket.
To evaluate the weight reduction achieved through topology optimization and compare it with the original bracket.
To assess the structural integrity of the optimized bracket using Ti-6Al-4V material properties, ensuring stresses remain within the yield strength limit (903 MPa).
To demonstrate the effectiveness of topology optimization as a design approach for aerospace components, focusing on lightweight design without sacrificing safety or reliability.