Structural design, manufacturing and testing of the new wing for the CSIR's Modular UAS in composite materials

In the framework of an international collaboration with South Africa CSIR, the structural design, manufacturing and testing of the new wing for the Modular UAS in composite materials has been performed.

Structural analysis of a UAV wing through image processing and FEM

Analisi strutturale dell’ala di un UAV (velivolo senza pilota a bordo), sviluppata usando varie metodologie: misurazioni sperimentali statiche e dinamiche, e simulazioni numeriche con l’utilizzo di programmi agli elementi finiti. L’analisi statica è stata a sua volta portata avanti seguendo due differenti metodi: la classica e diretta determinazione degli spostamenti mediante l’utilizzo di un catetometro e un metodo visivo, basato sull’elaborazione di immagini e sviluppato appositamente a tale scopo in ambiente Matlab. Oltre a ciò è stata svolta anche una analisi FEM volta a valutare l’errore che si ottiene affrontando il problema con uno studio numerico. Su tale modello FEM è stata svolta anche una analisi di tipo dinamico con lo scopo di confrontare tali dati con i dati derivanti da un test dinamico sperimentale per ottenere informazioni utili per una seguente possibile analisi aeroelastica.

Dimensionamento preliminare di un UAV e progettazione di un sistema di folding wing

L'elaborato descrive la metodologia utilizzata per il dimensionamento preliminare di un velivolo a pilotaggio remoto caratterizzato da un sistema propulsivo costituito da due motori a benzina. Successivamente viene trattata la progettazione concettuale di metodi per la riduzione degli ingombri dovuti all'ala quando il velivolo è al suolo.

Analytical model for the prediction of wrinkling of rear pressure bulkheads

In Airbus GmbH (Hamburg) has been developed a new design of Rear Pressure Bulkhead (RPB) for the A320-family. The new model has been formed with vacuum forming technology. During this process the wrinkling phenomenon occurs. In this thesis is described an analytical model for prediction of wrinkling based on the energetic method of Timoshenko. Large deflection theory has been used for analyze two cases of study: a simply supported circular thin plate stamped by a spherical punch and a simply supported circular thin plate formed with vacuum forming technique. If the edges are free to displace radially, thin plates will develop radial wrinkles near the edge at a central deflection approximately equal to four plate thicknesses w0/ℎ≈4 if they’re stamped by a spherical punch and w0/ℎ≈3 if they’re formed with vacuum forming technique. Initially, there are four symmetrical wrinkles, but the number increases if the central deflection is increased. By using experimental results, the “Snaptrhough” phenomenon is described.

Energy harvesting from piezoelectric devices embedded in a 3D printed wing

This thesis work has been carried out at Clarkson University in Potsdam NY, USA and involved the design of a low elongation wing, consisting of parts made by polylactide (PLA) using the fused deposition model (FDM) technology of Rapid Prototyping, then assembled together in a thin aluminum spar. The aim of the research is to evaluate the feasibility of collecting electrical energy by converting mechanical energy from the vibration of the wing flutter. With this aim piezoelectric stripes were glued in the inner part of the wing, as well as on the aluminum spar, as monomorphic configuration. During the phases of the project, particular attention was given to the geometry and the materials used, in order to trigger the flutter for low flow velocity. The CAD software SolidWorks® was used for the design of the wing and then the drawings were sent to the Clarkson machine shop in order to to produce the parts required by the wing assembly. FEM simulations were performed, using software MSC NASTRAN/PATRAN®, to evaluate the stiffness of the whole wing as well as the natural vibration modes of the structure. These data, in a first approximation, were used to predict the flutter speed. Finally, experimental tests in the Clarkson wind tunnel facility were carried out in order to validate the results obtained from FEM analysis. The power collected by the piezoelectrics under flutter condition was addressed by tuning the resistors downstream the electronic circuit of the piezoelectrics.

Geometric versus Model Predictive Control based guidance algorithms for fixed-wing UAVs in the presence of very strong wind fields.

The recent years have witnessed increased development of small, autonomous fixed-wing Unmanned Aerial Vehicles (UAVs). In order to unlock widespread applicability of these platforms, they need to be capable of operating under a variety of environmental conditions. Due to their small size, low weight, and low speeds, they require the capability of coping with wind speeds that are approaching or even faster than the nominal airspeed. In this thesis, a nonlinear-geometric guidance strategy is presented, addressing this problem. More broadly, a methodology is proposed for the high-level control of non-holonomic unicycle-like vehicles in the presence of strong flowfields (e.g. winds, underwater currents) which may outreach the maximum vehicle speed. The proposed strategy guarantees convergence to a safe and stable vehicle configuration with respect to the flowfield, while preserving some tracking performance with respect to the target path. As an alternative approach, an algorithm based on Model Predictive Control (MPC) is developed, and a comparison between advantages and disadvantages of both approaches is drawn. Evaluations in simulations and a challenging real-world flight experiment in very windy conditions confirm the feasibility of the proposed guidance approach.

Experimentally and coupled CFD/CSD assisted structural and aeroelastic modelling of the Javelin UAV outboard wing section

This study presents the procedure followed to make a prediction of the critical flutter speed for a composite UAV wing. At the beginning of the study, there was no information available on the materials used for the construction of the wing, and the wing internal structure was unknown. Ground vibration tests were performed in order to detect the structure’s natural frequencies and mode shapes. From tests, it was found that the wing possesses a high stiffness, presenting well separated first bending and torsional natural frequencies. Two finite element models were developed and matched to experimental results. It has been necessary to introduce some assumptions, due to the uncertainties regarding the structure. The matching process was based on natural frequencies’ sensitivity with respect to a change in the mechanical properties of the materials. Once experimental results were met, average material properties were also found. Aerodynamic coefficients for the wing were obtained by means of a CFD software. The same analysis was also conducted when the wing is deformed in its first four mode shapes. A first approximation for flutter critical speed was made with the classical V - g technique. Finally, wing’s aeroelastic behavior was simulated using a coupled CFD/CSD method, obtaining a more accurate flutter prediction. The CSD solver is based on the time integration of modal dynamic equations, requiring the extraction of mode shapes from the previously performed finite-element analysis. Results show that flutter onset is not a risk for the UAV, occurring at velocities well beyond its operative range.

Design of compliant mechanisms and their application to morphing wing technology

This thesis describes a study conducted for the development of a new approach for the design of compliant mechanisms. Currently compliant mechanisms are based on a 2.5D design method. The applications for which compliant mechanisms can be used this way, is limited. The proposed research suggests to use a 3D approach for the design of CM’s, to better exploit its useful properties. To test the viability of this method, a practical application was chosen. The selected application is related to morphing wings. During this project a working prototype of a variable sweep and variable AoA system was designed and made for an SUAV. A compliant hinge allows the system to achieve two DOF. This hinge has been designed using the proposed 3D design approach. To validate the capabilities of the design, two methods were used. One of these methods was by simulation. By using analysis software, a basic idea could be provided of the stress and deformation of the designed mechanism. The second validation was done by means of AM. Using FDM and material jetting technologies, several prototypes were manufactured. The result of the first model showed that the DOF could be achieved. Models manufactured using material jetting technology, proved that the designed model could provide the desired motion and exploit the positive characteristics of CM. The system could be manufactured successfully in one part. Being able to produce the system in one part makes the need for an extensive assembly process redundant. This improves its structural quality. The materials chosen for the prototypes were PLA, VeroGray and Rigur. The material properties were suboptimal for its final purpose, but successful results were obtained. The prototypes proved tough and were able to provide the desired motion. This proves that the proposed design method can be a useful tool for the design of improved CM’s. Furthermore, the variable sweep & AoA system could be used to boost the flight performance of SUAV’s.