Abstract:
Composite tooling for the automated fiber placement (AFP) of freeform aircraft intake ducts has a complex structure. Conventional stiffener design mainly relies on engineering experience and may not meet the high stiffness requirements of tooling. This study proposes a topology optimization-guided parting and stiffener design method. First, finite element analysis (FEA) is conducted to evaluate the structural response of the tooling. Topology optimization is then performed to identify the primary load-bearing regions. Based on the optimization results, the parting scheme is determined. The stiffener layout is subsequently designed according to the selected parting configuration. The effects of different parting locations and stiffener layouts on the tooling mass, stress distribution, and deformation are systematically investigated. The results show that under the local compaction loading of AFP, both the parting location and the stiffener layout have significant effects on the overall structural performance. The topology optimization-guided stiffener design effectively improves structural stiffness and optimizes its stress distribution. The proposed method provides a useful reference for the structural design of high-performance composite tooling used in the AFP manufacturing of complex aerospace components.