Multidisciplinary Optimisation of Aircraft Structures with Critical Non-Regular Areas: Current Practice and Challenges

The design optimisation of aerostructures is largely based on Multidisciplinary Design Optimisation (MDO), which is a set of tools used by the aircraft industry to size primary structures: wings, large portions of the fuselage or even an entire aircraft. The procedure is computationally expensive, as it must account for several thousands of loadcases, multiple analyses with hundreds of thousands of degrees of freedom, thousands of design variables and millions of constraints. Because of this, the coarse Global Finite Element Model (GFEM), on which the procedure is based, cannot be further refined. The structures represented in the GFEM contain many components and non-regular areas, which require a detailed modelling to capture their complex mechanical behaviour. Instead, in the GFEM, these components are represented by simplified models with approximated stiffness, whose main role is to contribute to the identification of the load paths over the whole structure. Therefore, these parts are kept fixed and are not constrained during the optimisation, as the description of their internal deformation is not sufficiently accurate. In this paper, we show that it would nevertheless be desirable to size the non-regular areas and the overall structures at once. Firstly, we introduce the concept of non-regular areas in the context of a structural airframe MDO. Secondly, we present a literature survey on MDO with a critical review of several architectures and their current applications to aircraft design optimisation. Then, we analyse and demonstrate with examples the possible consequences of neglecting non-regular areas when MDO is applied. In the conclusion, we analyse the requirements for alternative approaches and why the current ones are not viable solutions. Lastly, we discuss which characteristics of the problem could be exploited to contain the computational cost.