Finite Element Prediction of Residual Stress Field in an Additively Manufactured Aircraft Wing Rib Structure

This study explores the prediction of residual stress (RS) fields in an additively manufactured aircraft wing rib using finite element analysis (FEA), offering a transformative approach to improve structural performance in aerospace applications. The layered nature of additive manufacturing (AM) introduces significant residual stress due to thermal gradients, which can lead to part distortion and reduced fatigue life if not accurately managed. This project leverages advanced FEA simulations to model RS formation during both conventional and additive manufacturing processes, aiming to evaluate and compare the deformation behavior under operational loads. The 3D wing rib model, developed and analyzed using ABAQUS and ANSYS, incorporated validated material properties and layer-wise heat input simulation to replicate real-world AM conditions. Preliminary results indicate that optimized additive designs result in lower stress concentrations and improved distribution compared to traditionally manufactured counterparts. Validation of the simulation results is supported through the contour method and neutron diffraction measurements, ensuring realistic stress field estimations. The study supports sustainable engineering practices by minimizing material wastage and post-processing demands, aligning with the principles of environmental responsibility and manufacturing efficiency. Furthermore, the integration of design-for-AM strategies such as lattice infills provides added structural optimization. This research provides a foundation for future aerospace structural applications of AM, establishing a predictive and validated framework for residual stress management in critical load-bearing components.