Abstract:
Structural optimization tools such as OptiStruct enable design and stress engineers to visualize the most efficient load paths for a prescribed design space within the context of multiple load cases and boundary conditions. The main rotor gearbox (MRGB) team from the Sikorsky Boeing Joint Multi Role (JMR) SB>1 DEFIANT™ Aircraft leveraged these capabilities to streamline the development of complex gearbox housings. The benefits included more effective initial designs, reduced design / stress iterations and cycle time, and improved part weight performance. Based on experience from the JMR program, the practical application of optimization tools is discussed with a summary of advantages and limitations. In addition, several example applications from the SB>1 DEFIANT™ Aircraft MRGB are discussed in detail with an account of benefits observed and lessons learned.