Topology Optimization and Hybrid Manufacturing Analysis of a Ti-6Al-4V Engine Accessory Mounting Bracket for Regional Turboprop Aircraft.

  • Unique Paper ID: 205172
  • Volume: 13
  • Issue: 1
  • PageNo: 8421-8433
  • Abstract:
  • The aerospace industry is constantly seeking lighter and more efficient structural components to improve fuel economy and performance. This study explores the complete design optimization process of an Engine Accessory Mounting Bracket (used for generator or hydraulic pump support) intended for regional turboprop aircraft. Starting with a conventional baseline design, the bracket was first analysed under realistic flight and ground load conditions using finite element analysis. Topology optimization was then applied to reduce weight while maintaining structural strength. The optimized design was further evaluated for static performance and fatigue life. Finally, a detailed manufacturing comparison was performed between traditional 5-axis CNC machining and DMLS additive manufacturing, considering cost, production time, and material wastage. The results clearly demonstrate the advantages of combining topology optimization with additive manufacturing. This work highlights how modern design techniques can deliver significant improvements over conventional methods and provides practical guidance for aerospace component development.

Copyright & License

Copyright © 2026 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

BibTeX

@article{205172,
        author = {Henil Rangani},
        title = {Topology Optimization and Hybrid Manufacturing Analysis of a Ti-6Al-4V Engine Accessory Mounting Bracket for Regional Turboprop Aircraft.},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {13},
        number = {1},
        pages = {8421-8433},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=205172},
        abstract = {The aerospace industry is constantly seeking lighter and more efficient structural components to improve fuel economy and performance. This study explores the complete design optimization process of an Engine Accessory Mounting Bracket (used for generator or hydraulic pump support) intended for regional turboprop aircraft. Starting with a conventional baseline design, the bracket was first analysed under realistic flight and ground load conditions using finite element analysis. Topology optimization was then applied to reduce weight while maintaining structural strength. The optimized design was further evaluated for static performance and fatigue life. Finally, a detailed manufacturing comparison was performed between traditional 5-axis CNC machining and DMLS additive manufacturing, considering cost, production time, and material wastage. The results clearly demonstrate the advantages of combining topology optimization with additive manufacturing. This work highlights how modern design techniques can deliver significant improvements over conventional methods and provides practical guidance for aerospace component development.},
        keywords = {Topology Optimization, Aircraft Mounting Bracket, Ti-6Al-4V, Additive Manufacturing, DMLS, CNC Machining, Lightweight Design},
        month = {June},
        }

Cite This Article

Rangani, H. (2026). Topology Optimization and Hybrid Manufacturing Analysis of a Ti-6Al-4V Engine Accessory Mounting Bracket for Regional Turboprop Aircraft.. International Journal of Innovative Research in Technology (IJIRT), 13(1), 8421–8433.

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