The use of topology optimisation in the conceptual design of next generation lattice composite aircraft fuselage structures

TLDR

Conventional aircraft fuselages rely on aluminium semi‑monocoque skins with frames and stringers, yet further weight and cost reductions are limited as metal designs have reached near‑optimal efficiency. The study explores whether carbon‑fiber composites combined with lattice structures and topology optimisation, as investigated in the EU FP7 ALaSCA project, can achieve significant weight savings. The research culminated in a new airframe concept featuring a load‑carrying inner skin, transverse frames, helically arranged CFRP‑metal hybrid stiffeners in a grid, insulating foam, and an aerodynamic outer skin.

Abstract

Abstract Conventional commercial aircraft fuselages use all-aluminium semi-monocoque structures where the skin carries the external loads, the internal fuselage pressurisation and is strengthen using frames and stringers. Environmental and economic issues force aircraft designers to minimise weight and costs to keep air transport competitive and safe. But as metal designs have reached a high degree of perfection, extraordinary weight and cost savings are unlikely in the future. Carbon composite materials combined with lattice structures and the use of topology optimisation have the potential to offer such weight reductions. The EU FP7 project Advanced Lattice Structures for Composite Airframes (ALaSCA) was started to investigate this. This article present some of this research which has now led to the development of a new airframe concept which consists of: a load carrying inner skin; transverse frames; CFRP-metal hybrid stiffeners helically arranged in a grid configuration; insulating foam and an additional aerodynamic outer skin.