Energy finite element method-based topology optimization for aircraft control surfaces under thermo-vibrational coupling with experimental validation

The investigation of high-frequency dynamic optimization for high-speed aircraft structures operating under coupled thermo-vibrational conditions continues to represent a critical research frontier in contemporary aerospace structural engineering. The energy finite element method (EFEM) has established itself as a predominant computational technique for high-frequency vibration analysis in complex structural systems, owing to its computational efficiency and its ability to provide clear representations of energy density distributions. A substantial scientific gap remains in practical applications, as the combination of the EFEM and topology optimization has yet to be achieved for mitigating high-frequency vibrations in thermally loaded structures. To address this research gap, the present study develops an EFEM-based topology optimization framework specifically designed for mitigating high-frequency vibrations in typical control surface structures operating under thermal environments. Fundamental techniques, including thermo-vibrational coupling, solution algorithms, optimization models, and sensitivity analysis, were investigated under thermal conditions. For the first time, the proposed coupled thermo-vibrational topology optimization framework is applied to optimize typical control surface structures. The analysis shows that the method enhances the dynamic performance of the typical control surface structures by 11.28% to 66.08% under thermal conditions, with experimental validation confirming its efficacy in improving structural dynamics. The proposed framework exhibits strong extensibility, allowing other researchers to apply it to curved surfaces, complex spatial structures, or composite materials in various engineering fields.