Topology Optimization and Structural Design of a Fowler Flap Bracket for Additive Manufacturing Under Analytical Aerodynamic Loads

Abstract

Reducing structural weight in commercial aviation is a primary challenge for efficiency. This study introduces a design framework optimizing a Fowler flap bracket using topology optimization (TO) tailored for additive manufacturing (AM) constraints. Rather than expensive fluid simulations, the methodology utilizes analytical loads from Boeing 737 coefficients. Baseline analysis exposed an excessive safety factor of 15.8, highlighting mass reduction potential. Consequently, a SIMP optimization was executed under a 50% volume reduction target, embedding Laser Powder Bed Fusion (L-PBF) constraints. The reconstructed NURBS geometry achieved 49% mass reduction (1.65 kg to 0.85 kg) while preserving rigidity with 0.16 mm deformation. Static verification confirmed a safety factor of 10.72. Crucially, high-cycle fatigue analysis incorporating surface roughness penalties substantiated infinite life (10^8 cycles) and a minimum safety factor of 1.22. This validates the methodology's effectiveness in lightweighting critical aerospace components without compromising airworthiness.