Topology Optimization Design of a Hub Central Component Considering Fatigue Performance

To address the design challenges of helicopter hub central components under high-performance requirements, this paper conducts safe-life topology optimization design research considering fatigue performance for rotor hub central components under multi-load conditions, combined with helicopter fatigue strength engineering design theory. For dealing with the issues of derivative calculation difficulties when directly considering fatigue constraints in existing topology optimization methods, this study establishes a mathematical formulation suitable for structural topology optimization of hub central components by combining modified structural safety fatigue limits based on iso-life curves. Then the sensitivity analysis of design variables is derived, and an optimization design model for typical main rotor hub central components is constructed. By controlling the safe-life equivalent stress of the hub central structure, the goal of managing structural fatigue life is achieved, providing new insights for long-life, high-reliability hub central component design. The paper presents a topology optimization case study of a typical five-arm hub central component, completes optimized structure reconstruction and fatigue strength analysis, which validates the effectiveness of the proposed methodology.