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<p>This study presents an integrated framework for optimizing aircraft wing design, beginning with material selection using a Genetic Algorithm (GA)-based multi-objective optimization approach, incorporating Finite Element Analysis (FEA) constraints and multi-criteria decision-making, the GA assessed 12 aerospace-grade aluminum alloys, identifying a near-match to Aluminum 2024-T8510 as the optimal material for balancing strength, weight, and cost. Static analysis of four wing design iterations then identified WD-4 as the superior configuration, achieving a deformation of 18.21&#xa0;mm and a maximum stress of 204.81&#xa0;MPa, outperforming literature benchmarks (20&#xa0;mm, 208&#xa0;MPa) due to effective stiffening from spars and ribs. Subsequent topology optimization reduced WD-4’s weight by 25% with minimal increases in stress (0.06%) and deformation (7.91%), maintaining structural integrity. Buckling analysis further confirmed a load factor exceeding 1, ensuring resistance to local and global buckling despite significant material removal from ribs and spar webs. Validated against literature, this methodology demonstrates a robust strategy for lightweight, high-performance wing design, integrating material and structural optimization to advance aerospace engineering applications.</p> Graphical abstract <p></p>

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Multi-objective optimization of aircraft wing design: integrating material selection, structural analysis, and topology optimization

  • 期刊论文

  • 发表日期：

    2025年9月17日

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  • Muhammad Mubashir,
  • Ahmed Kadhim Zarzoor,
  • Anas Asim,
  • Mohsin Akhter,
  • Muhammad Shoaib-Ur-Rehman,
  • Muhammad Waqas

摘要

This study presents an integrated framework for optimizing aircraft wing design, beginning with material selection using a Genetic Algorithm (GA)-based multi-objective optimization approach, incorporating Finite Element Analysis (FEA) constraints and multi-criteria decision-making, the GA assessed 12 aerospace-grade aluminum alloys, identifying a near-match to Aluminum 2024-T8510 as the optimal material for balancing strength, weight, and cost. Static analysis of four wing design iterations then identified WD-4 as the superior configuration, achieving a deformation of 18.21 mm and a maximum stress of 204.81 MPa, outperforming literature benchmarks (20 mm, 208 MPa) due to effective stiffening from spars and ribs. Subsequent topology optimization reduced WD-4’s weight by 25% with minimal increases in stress (0.06%) and deformation (7.91%), maintaining structural integrity. Buckling analysis further confirmed a load factor exceeding 1, ensuring resistance to local and global buckling despite significant material removal from ribs and spar webs. Validated against literature, this methodology demonstrates a robust strategy for lightweight, high-performance wing design, integrating material and structural optimization to advance aerospace engineering applications.

Graphical abstract