Topology optimization of aircraft hydraulic pump casings for aerospace applications using lattice structures

In aerospace industry, topology optimization has emerged as an important tool that allows engineers to develop aircraft components with better performance characteristics and at the same time reduce their weight. This technique has also enabled the creation of complex structures and geometries that were not previously possible using conventional manufacturing methods. In this study, a comprehensive topology optimization of the front and rear cases of the Orenda jet engine hydraulic box using two lattice structures (Gyroid and Re-entrant) was performed using nTop. The main goal of this optimization was to make the front and rear cases lighter while maintaining their mechanical properties, which are crucial for the safe and reliable operation of the engine's hydraulic pump. This research shows that topology optimization can effectively reduce the weight of components while maintaining mechanical properties. Mass reductions of approximately 30–33% for the front casing and 36–37% for the rear casing were achieved depending on the lattice configuration, while strain values remained almost the same and stress values increased by 2-7% for one of the parts. The best results were obtained with the Gyroid lattice structure. This approach can be applied to other aircraft components that face similar design challenges and may allow significant weight savings in overall aircraft design.