Partially Optimised Wing Roller

Topology is Lightweighting

The organic nature of topologically optimised components can be clearly seen in the bone like structures created, although the ends of the wing roller pictured were left unchanged to draw test bars; later topological work on these reduced mass by an additional 10%. The free flowing design also enhances mechanical performance, further demonstrating the importance of geometry on mechanical characteristics.

Lightweight Aerospace Castings

The Foundry 2030 research project involved Sarginsons, Aerospace Technology Institute and numerous members of the Aerospace Industry. The project involved lightweighting a wing flap roller, a high stress, safety critical component. Despite being 30% lighter and a sand casting the redesigned component was deemed viable. Traditional castings could offer huge economies and benefits to the aerospace industry.

The Future of Lightweighting

Topological Optimisation is essentially the mathematics of lightweighting, but is rarely applied. Until recently, the number of variables involved has been too great to run accurate casting simulations. Sarginsons has turned this accepted wisdom on its head and can now transform the mass and performance of any component with the help of its unique digital twin simulations.

Key Points:

• Topology Optimisation Is Lightweighting.
• Casting Has Not Exploited Topology 
• Perfect For Cost and Weight Reduction in Aerospace. 
• Topology Enables Larger Castings 
• Aerospace Should be Using Traditional Castings

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