Aerostructural analysis and design optimization of composite aircraft

High-performance composite materials exhibit both anisotropic strength and stiffness properties. These anisotropic properties can be used to produce highly-tailored aircraft structures that meet stringent performance requirements, but these properties also present unique challenges for analysis and design. New tools and techniques are developed to address some of these important challenges. A homogenization-based theory for beams is developed to accurately predict the through-thickness stress and strain distribution in thick composite beams. Numerical comparisons demonstrate that the proposed beam theory can be used to obtain highly accurate results in up to three orders of magnitude less computational time than three-dimensional calculations. Due to the large finite-element model requirements for thin composite structures used in aerospace applications, parallel solution methods are explored. A parallel direct Schur factorization method is developed. The parallel scalability of the direct Schur approach is demonstrated for a large finite-element problem with over 5 million unknowns. In order to address manufacturing design requirements, a novel laminate parametrization technique is presented that takes into account the discrete nature of the ply-angle variables, and ply-contiguity constraints. This parametrization technique is demonstrated on a series of structural optimization problems including compliance minimization of a plate, buckling design of a stiffened panel and layup design of a full aircraft wing. The design and analysis of composite structures for aircraft is not a stand-alone problem and cannot be performed without multidisciplinary considerations. A gradient-based aerostructural design optimization framework is presented that partitions the disciplines into distinct process groups. An approximate Newton-Krylov method is shown to be an efficient aerostructural solution algorithm and excellent parallel scalability of the algorithm is demonstrated. An induced drag optimization study is performed to compare the trade-off between wing weight and induced drag for wing tip extensions, raked wing tips and winglets. The results demonstrate that it is possible to achieve a 43% induced drag reduction with no weight penalty, a 28% induced drag reduction with a 10% wing weight reduction, or a 20% wing weight reduction with a 5% induced drag penalty from a baseline wing obtained from a structural mass-minimization problem with fixed aerodynamic loads.