Multi-criteria optimization of an aircraft propeller considering manufacturing: Structural design optimization simultaneously considering a knowledge-based manufacturing and a structural model

Carbon-fiber-reinforced polymers are gaining ground; high mass-specific stiffness and strength properties in fiber direction are commonly identified as reasons. Nonetheless, there are great challenges unleashing the entire light-weight potential. For instance, the multitude of parameters (e.g. fiber orientations), also being linked with each other and having huge influence on, not only structural mechanics, but also onto effort in terms of manufacturing. Moreover, these parameters ideally need to be determined, such that mass and costs are minimal, while all structural and technical requirements are fulfilled. The challenge of considering manufacturing aspects along with structural mechanics are mainly addressed in this paper. It is outlining an approach for modeling manufacturing effort via expert knowledge and how to actually consider this model in a multi-criteria optimization framework. In addition, it will be shown how to incorporate these knowledge-based models into an efficient structural design optimization. For this sake, a braided propeller structure is optimized.