Aerodynamic-driven topology optimization of compliant airfoils

A strategy for density-based topology optimization of fluid-structure interaction problems is proposed that deals with some shortcomings associated to non stiffness-based design. The goal is to improve the passive aerodynamic shape adaptation of highly compliant airfoils at multiple operating points. A two-step solution process is proposed that decouples global aeroelastic performance goals from the search of a solid-void topology on the structure. In the first step, a reference fully coupled fluid-structure problem is solved without explicitly penalizing non-discreteness in the resulting topology. A regularization step is then performed that solves an inverse design problem, akin to those in compliant mechanism design, which produces a discrete-topology structure with the same response to the fluid loads. Simulations are carried out with the multi-physics suite SU2, which includes Reynolds-averaged Navier-Stokes modeling of the fluid and hyper-elastic material behavior of the geometrically nonlinear structure. Gradient-based optimization is used with the exterior penalty method and a large-scale quasi-Newton unconstrained optimizer. Coupled aerostructural sensitivities are obtained via an algorithmic differentiation based coupled discrete adjoint solver. Numerical examples on a compliant aerofoil with performance objectives at two Mach numbers are presented.