<p>Traditional spar-skin aircraft rudder faces critical challenges in simultaneously optimizing structural stiffness, mass reduction, and additive manufacturability. This study presents a synergistic multiscale optimization framework for aircraft rudder structural enhancement, integrating topology optimization (TO) with homogenization-based performance evaluation. The methodology combines macroscopic biomimetic dendritic stiffener design with microscopic hybrid lattice filling, including honeycomb and body-centered cubic (BCC) configurations. Homogenization methods derived equivalent mechanical properties for lattice-infilled domains, enabling efficient macroscopic modeling. Dynamic, static and aerodynamic performance was evaluated using finite element analysis (FEA) and computational fluid dynamics (CFD), achieving a 4.7% higher fundamental frequency and 7.3% reduced displacement compared to conventional spar-skin designs. Aerodynamic evaluation demonstrates the multiscale rudder’s superior performance, with 1.7% higher lift-to-drag ratio and enhanced control stability at a 9° deflection angle, validating its advantages in stiffness-weight efficiency and aerodynamic profile retention.</p>

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Synergistic Multiscale Topology Optimization and Homogenization Performance Evaluation for Aircraft Rudder Structural Enhancement

  • Yongli Zhang,
  • Shaoying Li,
  • Guangzhi Nan,
  • Bin Sun,
  • Yingchao Ma,
  • Chi Zhang,
  • Jiang Li

摘要

Traditional spar-skin aircraft rudder faces critical challenges in simultaneously optimizing structural stiffness, mass reduction, and additive manufacturability. This study presents a synergistic multiscale optimization framework for aircraft rudder structural enhancement, integrating topology optimization (TO) with homogenization-based performance evaluation. The methodology combines macroscopic biomimetic dendritic stiffener design with microscopic hybrid lattice filling, including honeycomb and body-centered cubic (BCC) configurations. Homogenization methods derived equivalent mechanical properties for lattice-infilled domains, enabling efficient macroscopic modeling. Dynamic, static and aerodynamic performance was evaluated using finite element analysis (FEA) and computational fluid dynamics (CFD), achieving a 4.7% higher fundamental frequency and 7.3% reduced displacement compared to conventional spar-skin designs. Aerodynamic evaluation demonstrates the multiscale rudder’s superior performance, with 1.7% higher lift-to-drag ratio and enhanced control stability at a 9° deflection angle, validating its advantages in stiffness-weight efficiency and aerodynamic profile retention.