Topology optimization for pressurized nonlinear structures using substructure and experimental studies

A compliant structure under fluidic pressure can undergo relatively large shape change, but the design of such type of structure is challenging as the pressure distribution depends on detailed structural geometry. In this study, a novel mixed substructure-density (MSD) model is proposed for topology representation and update in the optimal design of nonlinear compliant structures under quasi-static fluidic pressure. An optimization algorithm is developed via implementing the present model by using super-elements in commercial finite element analysis (FEA) software. Numerical examples are presented to validate the present model, algorithm, and designs numerically via full linear and nonlinear FEAs. A planar cellular network with five cells arranged in parallel is then designed for representing a pressurized wing rib structure capable of modulating airfoil thickness variation. The test results of the single-cell and five-cell PCS specimens prototyped using polyurethane material show that the respective cell thickness can be reduced by 11.9 and 6.4% respectively under a cell pressure of 250 kPa.