Finite element stress analysis and topological optimization of a commercial aircraft seat structure

Amaze, C D; Kuharat, Sireetorn; Bég, O Anwar; Kadir, Ali; Jouri, Walid; Bég, Tasveer A

Abstract

In recent years, the Finite Element Method (FEM) has emerged as a cornerstone in the field of seating design, particularly within the aircraft industry. Over the past decade, significant advancements in Finite Element (FE) analysis techniques have revolutionized the seat industry, enabling the creation of safer and more cost-effective seat designs. The accuracy of FE analysis plays a pivotal role in this transformation. In the process of constructing a reliable finite element model, the selection and precise manipulation of key parameters are paramount. These crucial parameters encompass element size, time scale, analysis type, and material model. Properly defining and implementing these parameters ensures that the FE model produces accurate results, closely mirroring real-world performance. Verification of Finite Element Analysis (FEA) results is commonly accomplished through experimental methods. Notably, when the parameters are appropriately integrated into the modelling process, FE analysis outcomes closely align with experimental results. This study aims to leverage the power of FEM in performing static stress analysis and topology optimization of aircraft seats using the SOLIDWORKS commercial finite element platform. By simulating loading conditions, this research calculates static stresses and displacements experienced by the aircraft seat. For AL7075-T6(SN) the structural analysis demonstrates that this material had a maximum stress of 125.2 N/mm 2 and a minimum stress of 0.0039 N/mm 2. Due to its strong 4.034 factor of safety, the component may have been over-engineered for its intended use. However, at 2.32 kg, the component's mass and $2.304/kg material cost showed a high design cost. The maximum Y-component of displacement was 0.0606 mm, which was acceptable but could have been optimized to decrease material use and expense without affecting structural integrity. After performing topology optimization on Simulation 1 of AL7075-T6(SN), several improvements have been achieved. The maximum stress sustained by the component has been elevated to 189.4 N/mm 2. However, it is worth noting that the minimum stress has also risen, although to a negligible value of 0.0006 N/mm 2. The compromise in this scenario is characterized by a fall in the factor of safety to 2.666, suggesting a design that is more optimal but possibly associated with more risk. The most notable improvements, however, concern weight reduction. The overall mass of the component saw a substantial reduction, reaching 1.89 kg, which represents a notable improvement on the original design. Through a comprehensive topology optimization study, the weight of the airplane seat is remarkably reduced by up to 30%, while still prioritizing passenger safety. The success of this optimization showcases the potential for substantial weight savings in aircraft seat design without compromising safety standards.

Citation

Amaze, C. D., Kuharat, S., Bég, O. A., Kadir, A., Jouri, W., & Bég, T. A. (in press). Finite element stress analysis and topological optimization of a commercial aircraft seat structure. #Journal not on list,

• Journal Article Type: Article
• Acceptance Date: Mar 20, 2024
• Deposit Date: Mar 20, 2024
• Journal: European Mechanical Science
• Electronic ISSN: 2587-1110
• Peer Reviewed: Peer Reviewed
• Keywords: Finite Element Method (FEM); Aircraft Seat Industry; FE Analysis; Static Stress Analysis; Topology Optimization; Experimental Validation; Material Model; Safety Standards; Weight Reduction; Seating Design