Topological Optimization of Polymer Composite Wing Ribs Using Parametric Modeling
Authors: Baranovski S.V., Glekov M.P.
Published in issue: #3(171)/2026
Category: Aviation and Rocket-Space Engineering | Chapter: Strength and Thermal Conditions of Aircraft
An increase in the weight efficiency of aircraft can be achieved by using composite materials in airframe design. Parametrical and topology optimization methods can be utilized to determine the optimum design parameters for load-bearing elements. The full potential of composite materials can be realized by using optimal lay-out in structural elements design. The automation of cutting and layering processes significantly reduces labor intensity. The paper discusses the design of the structural elements of an aircraft wing based on the application of parametric and topological optimization techniques. The issue of selecting appropriate geometric parameters for rib placement, thickness, and composite monolayer orientation angles is addressed. A topological optimization process is performed to optimize the shape of structural elements, considering aerodynamic and mass-inertia loads acting on the wing during the flight. Based on the results from solving a topological optimization problem using an objective function incorporating compliance, weight, and stress, four rib configurations are derived. It is found that the design with the lowest material density can significantly reduce the wing weight while meeting strength and stiffness requirements. To further enhance the specific characteristics of the wing, a parametric optimization of the monolayers orientation angles has been conducted. The optimized stacking sequence has been compared with a quasi-isotropic arrangement. It has been demonstrated that the implementation of an optimized configuration allows for a reduction in the magnitude of the applied stresses in the rib structures by 5%, while also increasing stiffness by 5%. This work represents the initial phase in the development of an optimized structural arrangement for aircraft wings.
EDN PYVDNY
References
[1] Timoshkov P.N., Goncharov V.A., Usacheva M.N., Khrul’kov A.V. Osobennosti tekhnologii i polymernye kompozitsionnye materialy dlya izgotovleniya kryliev perspektivnykh samoletov (obzor) [Features of technology and polymer composite materials for manufacturing aircraft wings (review)]. Trudy VIAM — Proceedings of VIAM, 2022, no. 1 (107), pp. 66–75. https://doi.org/10.18577/2307-6046-2022-0-1-66-75
[2] Guzeva T.A., Malysheva G.V. Osobennosti razrabotki konstruktorsko-tekhnologicheskikh resheniy pri proektirovanii detaley iz polymerov i kompozitov [Features of design and technological solutions development for parts made of polymers and composites]. Tekhnologiya metallov — Technology of Metals, 2022, no. 4, pp. 35–41. https://doi.org/10.31044/1684-2499-2022-0-4-35-41
[3] Baranovski S.V., Zai Ya Lin. Optimizatsiya konstruktsii kilya iz polymernykh kompozitsionnykh materialov za schet primeneniya biopodobnykh konstruktivno-silovykh skhem [Optimization of the keel design from polymer composite materials using bio-inspired structural schemes]. Nauchnyy vestnik MGTU GA — Scientific Bulletin of Moscow State Technical University of Civil Aviation, 2023, vol. 26, no. 2, pp. 37–48. https://doi.org/10.26467/2079-0619-2023-26-2-37-48
[4] Antsiferov S.I., Lozovaya S.Yu., Karachevtseva A.V., Sychev E.A. Development Methods for Pilotless Aircraft. Russian Engineering Research, 2024, vol. 44, no. 10, pp. 1479–1482.
[5] Reznik S.V., Apiev S.E. Composite air vehicle tail fins thermal and stress-strain state modeling. In: AIP Conf. Proc., 2021, vol. 2318, no. 1, art. 020012. https://doi.org/10.1063/5.0036561
[6] Mitrofanov O.V., Toropylina E.Yu. Opredelenie parametrov podkreplennykh panelei iz kompozitnykh materialov pri ogranicheniyakh po ustoychivosti s uchetom vliyaniya defektov pri szhatii i sdvige [Determination of parameters of reinforced composite panels under stability constraints considering defects in compression and shear]. Konstruktsii iz kompozitsionnykh materialov — Structures from Composite Materials, 2024, no. 2 (174), pp. 9–16.
[7] Lin Aung, Tatarnikov O.V., Wei Aung. Mnogokriterialnaya optimizatsiya kompozitnogo kryla bespilotnogo letatelnogo apparata [Multicriteria optimization of a composite wing for UAVs]. Izvestiya vysshikh uchebnykh zavedeniy. Mashinostroyeniye — Proceedings of Higher Educational Institutions. Mechanical Engineering, 2021, no. 11 (740), pp. 91–98.
[8] Korol’skiy V.V., Gavva L.M. Spektr optimalnykh tolshchin sloev, shaga stringerov i skhem ukladki paketov pri razmerno-vesovom proektirovanii kompozitnykh panelei nesushchikh poverkhnostey letatel’nykh apparatov s ogranicheniyami po utochnennoy teorii ustoychivosti [Spectrum of optimal layer thicknesses, stringer spacing, and layup schemes in weight-size design of composite panels of aircraft lifting surfaces]. Konstruktsii iz kompozitsionnykh materialov — Structures from Composite Materials, 2025, no. 2 (178), pp. 17–26.
[9] Kosykh P.A., Azarov A.V. Teoriya i analiz metodov topologicheskoy optimizatsii [Theory and analysis of topology optimization methods]. Inzhenerny zhurnal: nauka i innovatsii — Engineering Journal: Science and Innovation, 2023, iss. 4. https://engjournal.bmstu.ru/catalog/mech/mdsb/2264.html
[10] Ivchenko V.I., Shmelev A.V., Talaluev A.V., Omelyusik A.V. Metodicheskiye rekomendatsii po topologicheskoy optimizatsii silovykh konstruktsiy s primeneniem sredstv chislennogo modelirovaniya [Guidelines for topology optimization of structural components using numerical modeling]. Mekhanika mashin, mekhanizmov i materialov — Mechanics of Machines, Mechanisms and Materials, 2022, no. 4 (61), pp. 68–79.
[11] Sorokin D.V., Babkina L.A., Brazgovka O.V. Proektirovanie elementov konstruktsiy razlichnogo naznacheniya na osnove topologicheskoy optimizatsii [Design of structural elements based on topology optimization]. Kosmicheskiye apparaty i tekhnologii — Spacecraft and Technologies, 2022, no. 2 (40), pp. 61–82.
[12] Das G.K., Ranjan P., James K.A. 3D Topology optimization of aircraft wings with conventional and non-conventional layouts: A comparative study. In: AIAA AVIATION 2022 Forum. https://doi.org/10.2514/6.2022-3725
[13] Elelwi M., Calvet T., Botez R.M., Dao T.M. Wing component allocation for a morphing variable span of tapered wing using finite element method and topology optimisation — Application to the UAS-S4. Aeronautical Journal, 2021, vol. 125, no. 1290, pp. 1313–1336. https://doi.org/10.1017/aer.2021.29
[14] Kilimtzidis S., Kotzakolios A., Kostopoulos V. Efficient structural optimisation of composite materials aircraft wings. Composite Structures, 2022. https://doi.org/10.1016/j.compstruct.2022.116268
[15] Tun Lin Htet, Prosuntsov P.V. Optimizatsiya formy shpangoutov i uglov ukladki polymernogo kompozitsionnogo materiala silovogo nabora khvostovoy chasti legkogo samoleta [Optimization of wing ribs and ply angles of polymer composite material for the tail section of a light aircraft]. Izvestiya vysshikh uchebnykh zavedeniy. Mashinostroyeniye — Proceedings of Higher Educational Institutions. Mechanical Engineering, 2021, no. 9, pp. 97–107.
[16] Rahman M., Fricks C., Ahmed H., et al. Topology optimization and experimental validation of mass-reduced aircraft wing designs. Proceedings of the Institution of Mechanical Engineers, Part G: Journal of Aerospace Engineering, 2024, no. 239 (4), pp. 326–337.
[17] Chenglei Huang, Qingming Fan, Hongjun Liu, Boya Yu. Topology optimization design of wing rib based on bi-directional evolutionary structural optimization method. Xibei Gongye Daxue Xuebao / Journal of Northwestern Polytechnical University, 2025, no. 42, pp. 1005–1010.
[18] Wang Q.S., Wang S.Y., Li A.H. Topology optimization of wing ribs for additive manufacturing. International Journal of Vehicle Structures and Systems, 2023, vol. 15, no. 2, pp. 83–97.
[19] Badrukhin Y.I., Terekhova E.S. Vliyanie uglov orientatsii sloya na tolshchinu nesushchikh panelei iz sloistogo kompozita [Influence of ply angles on thickness of laminated composite panels]. Kosmicheskiye apparaty i tekhnologii — Spacecraft and Technologies, 2024, vol. 8, no. 4 (50), pp. 233–242.
[20] Hakan Demir, Necmettin Kaya. Multidisciplinary wing layout optimization. Defence Science Journal, 2025, no. 75, pp. 149–158. https://doi.org/10.14429/20144
[21] Kireev V.A., Kazakov I.A. Vybor ratsionalnykh parametrov kompozitnykh panelei krylya [Selection of rational parameters for wing composite panels]. Uchenye zapiski TsAGI — Scientific Notes of Central Aerohydrodynamic Institute, 2023, vol. 54, no. 3, pp. 89–100.
[22] Badrukhin Y.I., Terekhova E.S. Vybor ratsionalnogo paketa dlya kompozitnykh panelei kryla [Selection of rational layup for wing composite panels]. Obsche-rossiyskiy nauchno-tekhnicheskiy zhurnal “Polet” — All-Russian Scientific-Technical Journal “Polyot” (“Flight”), 2022, no. 2, pp. 72–76.
[23] Bogdanov A.P., Zorin Y.V., Koltsov M.A. Razrabotka konstruktorsko-tekhnologicheskikh resheniy po avtomatizatsii protsessa izgotovleniya krupnogabaritnykh izdeliy iz polymernykh kompozitsionnykh materialov aviatsionnogo naznacheniya [Development of design-technological solutions for automation of manufacturing large polymer composite aerospace components]. Aerokosmicheskaya tekhnika, vysokie tekhnologii i innovatsii — Aerospace Engineering, High Technologies and Innovations, 2021, vol. 1, pp. 30–34.