Mekatronik Mühendisliği Bölümü Koleksiyonu

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https://hdl.handle.net/20.500.13055/48

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Computational fluid dynamics-based aerodynamic performance evaluation of naca 64A206 airfoil using ansys fluent
(Euroasia Journal of Social Sciences & Humanities, 2026) Taş, Kerem Ali; Tanrıver, Kürşat; Ay, Mustafa
Aerodynamic performance evaluation of aircraft wings is a critical stage in aircraft design due to its direct influence on lift generation, flight stability, and overall efficiency. Computational Fluid Dynamics (CFD) methods provide an effective approach for predicting flow characteristics around airfoil geometries before experimental testing. Therefore, the objective of this study was to numerically investigate the aerodynamic behavior of the NACA 64A206 airfoil using ANSYS Fluent by evaluating velocity distribution, pressure variation, and lift coefficient characteristics.
Comparative analysis of quasi-symmetric and staggered inner-milling strategies under different toolpath patterns for deformation control of al 7075-T651 thin-walled plates
(Nature Research, 2026) Demirel, Yusuf Soner; Şentürk, İsmail Hakkı; Tanrıver, Kürşat; Ay, Mustafa
Deformation during the machining of thin-walled aluminum alloys is highly sensitive to residual stress redistribution and stiffness variation, representing a critical challenge in aerospace and precision manufacturing. In this study, the deformation behavior of Al 7075-T651 thin-walled plates was comparatively investigated under four machining strategies: contour-parallel (M1), quasi-symmetric sequential (M2), quasi-symmetric staggered (M3), and trochoidal-assisted staggered machining (M4). An integrated experimental–numerical framework combining coordinate measurement machine measurements and finite element method simulations was employed, while the initial material structure was characterized using X-ray diffraction (XRD). Under the investigated conditions, the M3 strategy exhibited the lowest deformation values of 0.109 mm and 0.116 mm during roughing and finishing, respectively. In contrast, the M1 and M4 strategies produced higher finishing-stage deformation values of 0.551 mm and 0.545 mm. The FEM model showed reasonable agreement with the validated M1 condition, yielding deformation values of 0.148 mm (simulation) and 0.126 mm (experimental). M1 provided the shortest roughing time (58 min), whereas M4 required the longest finishing time (70 min). The results suggest that toolpath strategy significantly influences deformation tendency and machining performance. The quasi-symmetric staggered strategy provided the best deformation–time balance, highlighting the potential of machining-sequence-based deformation control in thin-walled structures.
Reliable interpretation of extreme-heat energy response for sustainable campus management: Baseline, calendar, and chilled-water metering controls
(MDPI Publishing, 2026) Cihangir, Cenk; Özyılmaz, Lale; Coşkun, Yusuf
Open hourly meter data are often used to infer how buildings respond to extreme heat, but the interpretation can depend on the analytical baseline, institutional calendar, and meter configuration. We examined 60 education and office buildings in the Building Data Genome Project 2 using repeated whole-week validation, temperature-matched placebo tests, 13 academic-calendar definitions, and same-building, common-hour carrier com parisons. A leakage-resistant change-point model that incorporated a previous-day, load derived operating-regime proxy reduced blocked-validation error relative to a conventional model in 58 of 60 buildings; temperature binning provided no additional predictive benefit after regime control. Recovery-related signals were uncommon: rebound was significant in 2 of 49 eligible buildings, load-shape disruption in 1 of 49, and the 72 h duration diagnostic in 3 of 60. At Fox, the BASE calendar supported term and break comparisons through 39–42 ◦C, but neither building-use group differed significantly after false-discovery-rate ad justment; estimates above 42 ◦C were inconclusive. In the matched sample of 13 education and 10 office buildings, no electricity-only, chilled-water-only, or weighted specification provided robust evidence of a between-group difference. Across 99 combinations of carrier weight, normalization, and temperature bin, every 95% interval included zero. Reliable campus benchmarking therefore requires out-of-sample baseline assessment, explicit calen dar sensitivity, common-hour meter matching, and carrier-specific uncertainty reporting before building-use rankings or resilience-related interpretations are made.
Smart sanitary hardware for health monitoring
(Springer Nature Link, 2026) Yığcı, Defne; Özarslan, Olgaç; Özdalgıç, Berin; Çakıroğlu, Işıl; Tokyay, Begüm Kübra; Yetişen, Ali K.; Taşoğlu, Savaş
The development of point-of-care testing technologies can enable early diagnosis and regular monitoring of disease course and the response to medications. However, the need for a reliable home-based diagnostic technology that can be integrated with healthcare systems remains unmet. Urine is a rich bodily fluid containing distinctive biomarkers and nutrients, which can be obtained through non-invasive sampling. Here, strategies to re-engineer toilet systems for applications in health monitoring are discussed.
Aerostructural design and manufacturing of UAV wings: A systematic review
(Mehmet Bulut, 2026) Erol, Elif; Saldırıcı, Eren; Tanrıver, Kürşat; Ak, Mine
This systematic review aims to synthesize the multi-disciplinary optimization problem of Unmanned Aerial Vehicle (UAV) wing design, specifically addressing the conflicting requirements between maximizing aerodynamic efficiency and minimizing structural weight in high-aspect-ratio (>15) wings intended for long-endurance missions. Design/methods/approach: A total of 39 studies from the last 15 years were critically analyzed through an integrated perspective encompassing Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and advanced manufacturing technologies to identify systemic gaps in the design-to-production cycle. Findings/results: The investigation identifies the NACA 4412 airfoil as a primary reference geometry for low Reynolds number regimes due to its superior resistance to the Laminar Separation Bubble (LSB) phenomenon, which is shown to increase drag by up to 50%. Furthermore, the analysis reveals a critical modeling deficiency in current literature: the widespread "rigid wing" assumption neglects the aeroelastic negative twist (washout) effect in flexible structures, leading to a systematic lift overestimation error of approximately 7%. Regarding manufacturing, the study highlights that Z-axis anisotropy in topology-optimized structures produced via additive manufacturing leads to significant structural strength reductions of up to 50%. Conclusions: The review concludes that traditional sequential design paradigms are insufficient; successful UAV development is only achievable through an "Integrated Design (Co-Design)" approach where aerodynamic, structural, and manufacturing constraints are conducted concurrently to effectively bridge the quantifiable gap between digital simulation and physical workshop realities.
Clinical logistics robots: Architecture, HIS integration, and operational safety
(Mehmet Bulut, 2026) Baykal, Mert; Çiçek, Muhammet Nusret; Ak, Mine; Tanrıver, Kürşat
The critical personnel shortage and increasing logistical burden in global health systems are making hospital operations unsustainable, turning autonomous solutions into a strategic necessity. This study synthesizes the literature from 2015–2025 within the PRISMA protocol framework to examine the causal relationship between the technical architecture and clinical performance of autonomous mobile robots (AMR) in hospital logistics. Due to data heterogeneity, a qualitative synthesis method was adopted, and robotic systems were structured along the axes of "navigation, task, and kinematics." The findings reveal that despite the technological evolution from infrastructure-dependent vehicles to autonomous systems, a "high intelligence, low integration" paradox prevails in the clinical setting. The impact of architectural trade-offs, particularly between drive kinematics (holonomic and differential) and payload security, on clinical outcomes is significant. The most striking finding of this review is that robots with high technical autonomy capacity remain as "digital islands" disconnected from the workflow due to their inability to establish deep integration with Hospital Information Systems (HIS), thereby creating an "invisible workload" on staff. Consequently, the study proves that enhancing the clinical value of autonomous robots depends not on singular engineering improvements but on the adoption of standardized reporting protocols and the integration of technology as an institutional "infrastructure component.
Set üstü ocaklarında ışınım ve taşınımla ısı geçişinde verim artışı ve tasarruf için aparat geliştirilmesi
(Serüven Yayınevi, 2026) Karaali, Rabi; Akçay, Enes; Keven, Arzu; Zenk, Hilmi
Enerji talebindeki hızlı artış ve fosil yakıt rezervlerinin tükenme tehli kesi, küresel ölçekte enerji verimliliği politikalarının yeniden şekillenmesine neden olmaktadır. Uluslararası Enerji Ajansı (IEA) raporlarına göre, konut sektörü dünya genelindeki toplam nihai enerji tüketiminin yaklaşık %30’un dan sorumludur [1]. Bu tüketim kalemleri arasında ısıtma ve soğutmadan sonra en büyük payı pişirme faaliyetleri almaktadır. Özellikle gelişmekte olan ülkelerde evsel enerjinin önemli bir kısmının pişirme eylemi için harcandığı ve bu süreçteki verimsizliğin karbon emisyonlarını doğrudan artırdığı bilin mektedir [2]. Bu bağlamda, pişirici cihazların termodinamik verimliliğinin artırılması, küresel sürdürülebilirlik hedefleri için kritik bir adımdır.
Tepsili bir kurutucuda deveci ve santa maria armut dilimlerinin kurutma performansları ve enerji ekserji analizi
(Serüven Yayınevi, 2026) Karaali, Rabi; Keven, Arzu; Cimşit, Canan; Zenk, Hilmi
Dünyada enerji talebindeki artış, sınırlı fosil kaynaklar ve çevre kirliliği gibi faktörler nedeniyle temiz ve verimli enerjinin önemini artırmış ve dikkatleri üzerine çekmiştir. Gıdaları muhafaza etmenin en eski ve en iyi yöntemlerinden biri kurutma işlemidir. Bu işlem temel olarak ısı enerjisini kullanarak katı gıdadaki nemin uzaklaştırılması olarak tanımlanabilir. Gıda kurutma işleme tesislerinde gıdanın nem içeriğini azaltmak amacıyla yapı lan işlemlerde akışkan yataklı, kesikli, tepsili ve güneş enerjisiyle kurutma yöntemleri yaygın olarak kullanılmaktadır. İşlemin temel amaçları su aktivitesinin azaltılması, bozulmanın önlenmesi ve gıdanın hacim ve ağırlığının en aza indirilmesi olarak vurgulanabilir. Bu yönüyle kurutma işlemi tarım alanları için raf ömrünü uzatması, paketleme maliyetini düşürmesi, lezzetini ve besin değerini koruması nedeniyle bir zorunluluktur.
Performance and exergy analyses of GT-MHR nuclear cycles
(Prof. Dr. İskender AKKURT, 2026) Akçay, Enes; Keven, Arzu; Karaali, Rabi
In this study, the performance and exergy analyses of the GT-MHR type nuclear power plants with high thermal energy were analysed. The GT-MHR(GasTurbine-Modular HeliumReactor), produces electricitybyusing helium gas inthe Brayton cycle, and utilizes the waste heat of the system with the Rankine cycle. The Brayton cycle allows helium gas to be heated to high temperatures in the reactor core, then converted into mechanical energy by usinga gas turbine. This hybrid structuresin the designsof GT-MHRsallow the combined use of nuclear and renewable energy sources.It was foundthat exergy efficiency reached its maximum level between approximately 14,000 -16,000 kPa. At this point, the exergy losses of thissystem approach itslowest level and the components reach the most ideal operating conditions. If the system is operated below or above of this value, the total exergy efficiency will decrease. The exergy efficiency, which is initially approximately 74.5% at 500 kPa pump pressure, increases to 75.1% at 1000 kPa pressure level. While the pump pressure at 500 kPa produces a work of approximately 532,000 kW, at 1000 kPa it increases to 560,000 kW. Thus, GT-MHR pioneers the energy technologies of the future by combining both high efficiency and environmental sustainability.
Exergy analysis and optimization of combined brayton and rankine cycles
(Prof. Dr. İskender AKKURT, 2026) Bozkurt, Ali; Keven, Arzu; Karaali, Rabi
There are many energy sources on the World that can be classified as renewable and non-renewable energies. The non-renewable energies which are exhaustible and often harmful to the environment. The usage of all these renewable and non-renewable energies efficiently is very important in technology and industry. The concept of exergy and exergy analysis is very important methods to show the inefficiencies and the irreversibility’s in a system and its devices. In this study, exergy analysis methods are applied to efficient combine cycle and cogeneration systems. The destruction of exergy has been examined for combined cycles and cogeneration system to find the optimum working conditions. It is found that as the pump pressure of the Rankine cycle increases from 400 kPa to 7600 kPa, the exergy efficiency increases from 76% to 85%, and as the compression pressure of the Brayton cycle increases from 400 kPa to 2200 kPa, the exergy efficiency increases from 72% to 79%. When these operating conditions, where the two cycles will operate at their optimum, are applied together, the exergy efficiency of the all cycle exceeds 86%. When the operating conditions, where the Brayton and Rankine cycles are at their maximum efficiency, are applied together, the optimum operating conditions of the system are obtained.
Performance and exergy analysis of cryogenic cycles
(Prof. Dr. İskender AKKURT, 2026) Çeker, Hüsniye; Öztekin, Erman Kadir; Keven, Arzu; Karaali, Rabi
This study examines and demonstrates the concepts of thermodynamics, exergy, and exergy analysis, and shows how these principles are applied to cryogenic cycles using equations. Furthermore, an energy, exergy, and performance analyses of the two-stage vapor compression cascade cryogenic cycle for natural gas liquefaction is conducted, and optimum operating conditions are presented in tables. Based on the data obtained from these equations, exergy analysis of cryogenic cycles was performed, and performance analysis and curves were plotted. When the compressor outlet pressures of the first sub cycle is increased from 3300 kPa to 4590 kPa, the exergy loss of the devices decreases, the exergy efficiencies of the increases, and the COP values increase. When the cooling amount in heat exchangers 1 and 2 is increased from 9 °C to 17 °C, i.e., when cooling is increased, it leads to a slight improvement in the performance of the system. The optimum total compressor consumption according to inlet/outlet temperature difference in heat exchangers 1 and 2 are obtained at about 14-15 °C. When these two improvement methods are applied together, optimum performance values of the system are obtained. The COP value increases from 0.078 to 0.1164. The system is affected by the compressor outlet pressure of the first sub cycle. Increasing the cooling level from 9°C to 17°C in heat exchangers 1 and 2 has a minor impact on system performance.
Development of apparatus for increasing efficiency and savings in radiation and convection heat transfer in stovetops
(Prof. Dr. İskender AKKURT, 2026) Karaali, Rabi; Akçay, Enes; Keven, Arzu
A new apparatus is designed to increase the efficiency and save fuel in electric and gas stoves used in kitchens. Through analyses and experiments, improvements are made to this apparatus to utilize a larger amount of heat lost through convection and radiation, thus saving electricity and gas fuel used in stoves. Initial and final heat values and cooking energies is compared. A test unit is prepared for this purpose, using an electric and gas stove, a pot with a diameter of approximately 17 cm, and a specific amount of water. Equipment used will include a thermometer, a stopwatch, and a thermal camera. Different diameter and thickness designs of the apparatus is created. These are incorporated heat insulation material to facilitate heat transfer to the outside environment: radiant heat transfer via a bright inner surface, conductive heat transfer via the insulation material, and convective heat transfer by lowering the outer surface temperature with the insulation material. The apparatus is designed with lower openings for air intake to improve gas combustion and upper openings for exhaust outlet. In the experiments, the time it takes for water in a steel pot to reach 80°C is determined for various designs of the appliance on a natural gas stovetop, and the efficiency increases and results are shown graphically. Lots of experiments done and the figures show for electric stove that uninsulated round without sheet metal plates the best performance with 9 minutes obtained for electric stove. For gas stove, with the device developed from 0.5 mm steel the temperature rises from 20°C to 80°C in 9 minutes, which is the best performance among all of the other alternatives.
Topology optimization of snake-like robot limb using ansys
(Fytronix Elektronik Teknolojileri, 2023) Coşkun, Yusuf; Aydın, Muhammet; Koçak, Muhammed Tayyip
Recent natural disasters lead to the formation of large amounts of debris and consequently to the trapping of living creatures among the debris. A search and rescue robot inspired by the morphology of a snake has been designed to effectively reach the trapped creatures in these challenging conditions. Optimization of the body limb is of great importance for the robot to perform fast, agile, and durable in narrow and complex areas under debris. In this study, a topology optimization analysis of the robot's limb is performed using Ansys software. The optimization is focused on the body limb, which is the basis of the snake's mobility. The main objective of this study is to achieve significant optimization of the mass and volume parameters for the robot's body limb while maintaining structural robustness. Thus, the overall design of the robot is aimed to be more compact and efficient, while achieving more effective mobility in narrow and difficult areas under debris. As a result of detailed analysis, a significant decrease in stress and strain values was found. However, an increase in deformation values was observed. The fact that this increase occurs in deformation indicates that some parameters of the model deviate from the expected results. Furthermore, the investigation revealed that the mass and volume of the model decreased by half. This shows the potential of topology optimization in terms of material utilization and structural efficiency. However, the increase in deformation indicates that the current parameters of the model should be reviewed. Consequently, it has become imperative to revise the selected parameters to further improve the performance of the model and achieve the expected mechanical properties. This study successfully demonstrates how lighter and more durable structures can be achieved through topology optimization with efficient use of resources.
Topology optimization for flexible robotic gripper using ansys
(Fytronix Elektronik Teknolojileri, 2024) Dib, Kusay; Aydın, Muhammet; Coşkun, Yusuf
This study investigates the application of topology optimization techniques to enhance the structural design of a flexible robot gripper, with a specific focus on utilizing PLA (Polylactic Acid) material. Through iterative processes of static analysis and topology optimization, the primary objective is to develop a gripper design that strikes a balance between lightweight construction and structural robustness. The research employs SolidWorks for model creation and Ansys for static analysis, meshing, and optimization. Key optimization strategies include volume optimization, mass optimization, and remodeling. The findings demonstrate significant achievements in mass reduction, with post-optimization models showcasing a remarkable 34.35% decrease. This reduction in mass not only contributes to the overall efficiency of the gripper but also aligns with sustainability goals by minimizing material usage. Moreover, the study highlights the importance of volume optimization in enhancing structural efficiency and performance. These advancements underscore the effectiveness of topology optimization methodologies in achieving lightweight yet robust designs, particularly in the context of flexible robot grippers. The findings contribute to the broader discourse on sustainable engineering practices and pave the way for further advancements in the field of robotics. Additionally, the study emphasizes the need for continued exploration into alternative material options and further refinement of optimization techniques to meet evolving design challenges in robotics and beyond.
Symmetry-breaking and fault-tolerance analysis of a twelve-legged jansen robot using a hybrid FEA-ANFIS framework
(MDPI Publishing, 2026) Coşkun, Yusuf; Koçak, Zakir; Akgüngör, Eren; Özyılmaz, Lale; Özyılmaz, Yakup Hakan
This study presents a comprehensive symmetry-breaking analysis framework for a twelve legged Jansen walking robot, integrating finite element analysis (FEA) with adaptive neuro fuzzy inference system (ANFIS) surrogate modeling. A systematic dataset of 210 cases was generated by combining 21 single- and multi-leg failure scenarios across 10 load levels (20–200 N) on the PLA-based 3D-printed prototype. Two novel dimensionless metrics are introduced: the Resilience Index (RI), quantifying the proportional stress increase relative to the baseline, and the Asymmetry Index (AI), measuring leg-reaction force distribution imbalance. Results identify a clear fault-tolerance threshold between two- and four-leg failures: single-leg failures remain at LOW risk (RI < 0.20), while three-leg asymmetric failures (S18) reach CRITICAL level (RI = 1.13, ~97% of PLA yield strength). A hybrid machine learning framework is proposed, applying ANFIS to maximum stress (R2 = 0.817) and safety factor (R2 = 0.936) predictions, while reserving FEA tables for bimodal out puts. The ANFIS surrogate achieves approximately 106× speedup over FEA (262.6 µs vs. 5–8 min), enabling real-time fault diagnosis and digital twin applications. The framework is generalizable to other multi-legged robotic systems requiring fault-tolerance evaluation.
Structural analysis and topology optimization of a mobile robot chassis for STEM education
(Adiyaman University, 2026) Yazar, Zeynep; Coşkun, Yusuf; Özyılmaz, Lale
This study investigates the structural analysis and topology optimization of a Theo Jansen mechanism-based mobile robot chassis, developed to help primary school students learn engineering fundamentals. Finite element analyses were performed in ANSYS, including static and modal analyses, followed by topology optimization to reduce mass while preserving strength. The pre-optimization model showed 0.2597 mm deformation and 3.5248 MPa stress, whereas the optimized design had 0.4885 mm deformation and 3.7745 MPa stress. Optimization reduced mass by 37% in simulation (15.625 g to 9.8925 g) and 26.3% after 3D printing (10.31 g to 7.60 g). Modal analysis revealed six natural frequencies, used to guide motor selection and avoid resonance. Results were simplified for students through ratio, proportion, and percentage exercises, supported by visuals and models. Future work includes applying the activities to larger groups and evaluating learning outcomes using artificial neural networks and fuzzy logic.
Static and dynamic analysis of a 12-legged walking robot manufactured using additive manufacturing
(Afyon Kocatepe Üniversitesi, 2026) Coşkun, Yusuf; Koçak, Zakir; Çalışır, Salih; Akgüngör, Eren
In this study, a 12-legged walking robot with a Theo Jansen-type mechanism, manufactured using additive manufacturing, was thoroughly analyzed using the Finite Element Method for static, dynamic, and modal analyses. The static analysis yielded a maximum Von-Mises stress of 7.02 MPa, a maximum total deformation of 0.025 mm, and a minimum safety factor of 12.28. The modal analysis found the first natural frequency to be 71.57 Hz, indicating no risk of resonance with the drive motor's operating frequency. In the time-dependent analysis, the maximum stress during the full step cycle of the leg mechanism was 9.50 MPa. Topology optimization resulted in a 25% reduction in material on the main supporting structure, thereby reducing costs, and the minimum safety factor was determined to be 9.07. The results obtained demonstrate that the robot design operates safely under both static and dynamic loads. The findings obtained demonstrate that the design has a safe and stable structural performance under working conditions.
Localization of a high strength and vibration resistant fastening element for the defense industry
(Liberty Academic Publishers, 2026) Demirel, Yusuf Soner; Şentürk, İsmail Hakkı; Tanrıver, Kürşat; Ay, Mustafa; Şahin, Ethem İlhan
In the modern defense and aerospace industry, maintaining the structural integrity of air platforms and optimizing their operational life cycles are directly dependent on the high-precision domestic production of critical components. The indigenization of strategic parts not only minimizes foreign dependency but also ensures supply chain security against embargo risks and international logistical disruptions. This study comprehensively addresses the localization and technical validation processes of a specialized structural pin, which serves as a primary fastener in aerospace structures, aircraft wings, and missile systems, characterized by high strength and vibration damping capabilities. Within the scope of the research, Al 7075-T6 aluminium alloy, a premium material in aerospace standards known for its superior strength-to-weight ratio, was selected as the raw material. During the manufacturing phase, "Swiss-Type Lathe" (Sliding Headstock) technology was utilized to provide high dimensional stability in tight-tolerance geometries, and samples underwent heat treatment processes in accordance with aerospace norms. The mechanical performances of the manufactured specimens were subjected to static and dynamic tests within the framework of internationally recognized NASM1312 standards. In the design validation phase, non-linear static Finite Element Analysis (FEA) was performed using ANSYS software. In these numerical simulation processes, based on experimental data obtained from physical testing equipment, displacement values of 0.55 mm for tensile analysis and 0.23 mm for double shear analysis were defined as boundary conditions in the system. When the numerical analysis results were compared with the experimental data obtained from production samples, a high-correlation alignment was determined with an acceptable deviation of approximately 5%. The fact that both tensile and double shear strength values exceeded the minimum limits specified by the standards, and that the physical fracture lines perfectly overlapped with the plastic deformation zones in the simulation model, proves the reliable applicability of domestic production in critical defense systems with concrete and scientific data.
Fixture design for high-strength fasteners and the effect of surface clearance on test results
(Liberty Publishing House, 2026) Demirel, Yusuf Soner; Acar, Ayberk Okan; Tanrıver, Kürşat; Ay, Mustafa; Sinha, Thuna
In this study, the effects of fixture designs and surface clearance tolerances on test results were investigated for the shear performance of high-strength fasteners, such as 7075-T6 aluminum, which are of critical importance in aerospace assemblies. With reference to ISO 8749 (maximum clearance of 0.15 mm) and NASM 1312-13 (maximum clearance of 0.0125 mm), the performance of compression-type and tension-type fixtures was comparatively evaluated using the Finite Element Method. The analyses were conducted in ANSYS 2025, employing mesh sizes of 0.6 mm for the pin, 0.8 mm for the hole surfaces, and 0.05 mm for the shear region. For fixture material selection, AISI 4140, Toolox 40, and AISI 4340 steels were assessed; AISI 4140 was found to be sufficient to meet the target yield strength criterion of 1.5 times the tensile strength of 7075-T6 aluminum. According to the simulation results, undesired stress levels on the order of 500 MPa were observed on surfaces outside the shear plane in the tension-type fixture. Consequently, the compression-type fixture, which concentrates stresses more effectively on the shear plane, was preferred. To examine the effect of tolerance between the fixture walls, analyses were performed for clearance scenarios of 0.3 mm and 0.025 mm. For these two clearance values, the maximum von Mises stresses were calculated as 641 MPa and 643 MPa, respectively, while the maximum shear stresses were 370.42 MPa and 370.95 MPa. These results, obtained for an 8 × 28 mm pin geometry, indicate that tolerance tightness does not lead to a statistically significant difference in stress outcomes. Consequently, it was concluded that ISO-compliant designs with relatively looser tolerances can be employed to reduce manufacturing costs without compromising test reliability.
Weapon pylon structure topology optimization and stress comparison
(Liberty Publishing House, 2026) Akın, Furkan; Ay, Mustafa; Tanrıver, Kürşat; Sinha, Tuhina
This study focuses on the structural optimization of an aircraft weapon pylon by topology optimization techniques under realistic operational loading conditions. Weapon pylons are critical load bearing components that enable aircraft to carry external stores such as missiles, fuel tanks, and sensor pods. Due to their function, these structures are exposed to complex combinations of aerodynamic forces, inertial loads, and operational stresses, which can significantly influence both flight safety and overall aircraft performance. Therefore, achieving an optimal balance between structural strength and weight reduction is a key design objective in aerospace applications. In this research, multiple load cases representing different flight conditions were defined in accordance with commonly accepted military and aerospace design standards to ensure realistic boundary conditions. The baseline weapon pylon geometry was modeled and analyzed using finite element methods to identify stress distributions and critical regions. Aluminum alloy was selected as the structural material due to its high strength-to-weight ratio, good fatigue performance, and widespread use in aerospace structures. Topology optimization was performed with different mass fraction constraints, specifically 0.4, 0.5, and 0.6, resulting in three optimized design configurations with varying material distributions. The optimized density layouts were subsequently interpreted and transformed into manufacturable solid geometries while preserving the main load paths identified during the optimization process. These redesigned models were then subjected to detailed stress analyses to evaluate their structural performance and to compare them with the original, non-optimized configuration. The results highlights the trade-off between lightweight design and structural durability in weapon pylon structures. Overall, this work presents a practical and systematic methodology for integrating topology optimization with numerical validation, contributing to the development of more efficient and reliable aerospace structural components.

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