Topology optimization of Oil tank supports

Abstract

Reducing structural mass while maintaining mechanical integrity is a key objective in the aeronautical industry, as it directly contributes to improved efficiency and reduced emissions. In this context, the present work investigates the application of topology optimization to an aircraft engine oil tank support system, intending to achieve mass reduction while ensuring rigorous structural performance under combined static and dynamic loading conditions. The support system consists of three main components—triangles, lugs, and brackets—and is analyzed within an industrial framework using ANSYS Mechanical. Since topology optimization in ANSYS is restricted to static loading formulations, dynamic effects are addressed through subsequent modal and harmonic analyses performed for validation purposes. The methodology combines static, modal, and harmonic reference analyses with multiple topology optimization studies, focusing on the influence of design-space definition, mesh resolution, retained mass limits, stress constraints, and projection parameters. The results demonstrate that the optimization outcome is strongly governed by the size and stiffness of the design space, mesh density, and the interaction between optimized and non-optimized regions. Sensitivity analyses highlight the importance of appropriate parameter selection to obtain stable and physically meaningful topologies. Among the investigated formulations, compliance minimization combined with stress and mass constraints provides the most consistent and robust results across different configurations. Validation under static and dynamic loading confirms the relevance of the optimized designs, while also revealing limitations related to mesh dependency and load-path sensitivity. Overall, this study illustrates both the potential and the limitations of industrial topology optimization workflows applied to complex structures. It provides practical insights and guidelines for the effective use of topology optimization as a design-support tool rather than a direct geometry-generation method.