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Topology Optimization of an Aircraft Tray Table

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What?

  • The project focused on optimizing the aircraft tray table assembly to reduce weight while maintaining structural integrity.
  • The primary components optimized were the tray table arm (Al2024-T3) using Topology Optimization and Finite Element Analysis (FEA).
  • The designs were evaluated for CNC machining, balancing weight reduction, manufacturability, and cost efficiency.

How?

  • Baseline FEA Analysis: Conducted finite element analysis (FEA) on the existing design under FAA standard loads (670N downward force) to establish stress distribution and weight.
  • Topology Optimization: Used ANSYS to remove low-stress material while maintaining structural integrity, retaining 60% of the mass in key load-bearing regions.
  • Redesign for Manufacturing: Designed truss-like cutouts for manufacturability while retaining strength.
  • FEA Validation of Optimized Design: Verified stress distribution, achieving a safety factor of 1.12 while reducing material.

Result

  • Significant Weight Reduction: Reduced mass from 44.45g to 35.91g (19.2%)
  • Structural Integrity Maintained: Verified using FEA, ensuring FAA compliance.
  • Fuel Efficiency Gains: Saves 2.9 kg per aircraft, reducing fuel costs by $33,292 per year per plane.

Project Images

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