Novel design of an airplane split wheel based on the hybrid topology and shape optimisation

A specific two-piece wheel is used for tyre/wheel assembly testing at the Aviation Tyres Science Centre, and the current research focuses on wheel optimisation. First, two load cases of the tyre/wheel assembly testing are introduced, including pure vertical force (extreme loading condition I) and combined vertical/lateral force (extreme loading condition II). FE analysis is performed using the intact wheel model, which provides von Mises stress and structural deflection under extreme loading conditions. Then, the intact wheel model is optimised using topology and shape optimisation methods. The topology optimisation aims to refine the wheel cross section. Subsequently, the shape optimisation is carried out by the combined global and local search. After the hybrid optimisation, the final wheel model squeezes 44.7% of the total material volume of the intact wheel model, while still fulfilling the strength requirements in terms of von Mises stress, structural deflection, and safety factor.