METROLOGIA-2003 – Metrologia para a Vida

Sociedade Brasileira de Metrologia (SBM)

Setembro 01−05, 2003, Recife, Pernambuco - BRASIL

DEVELOPMENT OF 2 AND 3-D AERODYNAMIC TESTING TECHNOLOGY

FOR HIGH PERFORMANCE AIRCRAFT DESIGN

Mello O. A. F. 1 , Reis M. L. C. C. 2 , Komatsu P. 3 , Alvim R. S. 4 , Chisaki M. 5

1
Centro Técnico Aeroespacial, São José dos Campos, Brasil
2
Centro Técnico Aeroespacial, São José dos Campos, Brasil
3
Empresa Brasileira de Aeronáutica, São José dos Campos, Brasil
4
Centro Técnico Aeroespacial, São José dos Campos, Brasil
5
Centro Técnico Aeroespacial, São José dos Campos, Brasil

ABSTRACT cost reduction. Nowadays this tendency is reality in the

aeronautical industry, as manufactures have to develop their
To modernize and increase productivity of the Subsonic
products in periods of time compatible with demand and
Wind Tunnel No. 2 (TA-2), of the Aerodynamic Laboratory
prior to their competitors.
(ASA-L), of the Centro Técnico Aeroespacial (Aerospace
Considering that wind tunnel tests effectively determine the
Technical Center, CTA), Brazil, are the objectives of the
schedule of an airplane development program, it is
Technological Inovation Project. This project is being
mandatory to improve aerodynamic tests in terms of
carried out in partnership with the Empresa Brasileira de
delivering final reliable data quickly. This Technological
Aeronáutica (EMBRAER), Universidade de São Paulo (São
Inovation Project is focused on the application of new
Paulo State University, USP) and the Fundação de Amparo
methodology to increase the productivity and reliability of
à Pesquisa do Estado de São Paulo (Foundation for Support
low speed aerodynamic tests conducted in Brazil, in order to
of Research of the State of São Paulo, FAPESP). Part of the
supply support to the national aeronautical industry. Rather
process to meet the requirements for the competence of the
than one large and costly renovation of the facility, the
aerodynamic laboratory TA-2 includes: implementing
modernization proposed here is a kind of a continual
documented and reliable data acquisition and reduction
upgrading. This method would provide flexibility to identify
software, elaborating technical and management
the highest priorities and integration between old and new
documentation related to uncertainty evaluation and
technologies [1]. The proposed steps to implement the
measurement and administration procedures, validating
project are:
calibration and test procedures, and training personnel in
metrology and modern experimental techniques. The − Improvement of the productivity of the tests;
strategy of the modernization employs a continual process − Improvement of the reliability of the tests;
of upgrades of the TA-2 facility and aims at increasing the − Development of methodology of 2-D tests; and
aerodynamic test productivity, the improvement in data − Development of methodology of correlation of 2- and 3-D
quality, the development of methodology of 2-dimensional tests.
tests and the development of methodology of correlation
between 2- and 3-dimensional tests. This paper describes the 2. THE WIND TUNNEL FACILITIES
steps adopted in order to improve reliability, to reduce costs
and to enhance the data quality of the tests conducted at TA- The studies developed in this project are carried out
2 facility. The assessment of the uncertainty of the loads that basically in three facilities.
act on the model being tested is presented.
2.1. The TA-2

Key words : wind tunnel test, uncertainty, technological
inovation.
1. INTRODUCTION
As the commercial aircraft industry deals with complex
products which encorporate the integration of several
subsystems, traditionally there are long periods from the
design of new products up to their efective final market
delivering. In recent years, the industry, in general, has
sought to increase design efficiency, coupled with time and
The Aerodynamic Tunnel no. 2 (TA-2) of the Centro
Técnico Aeroespacial (CTA). The TA-2 has been in service
for over thirty years and has been used for many aerospace
projects, mostly Embraer aircraft. The subsonic wind tunnel
TA-2, which is the largest in Latin America, has a test
section measuring 2.1 by 3.0 meters (7 by 10 ft). (Figure 1).
There are two laboratories, the Low Pressure Laboratory and
the Low Force Laboratory, connected to TA-2, which
provide support for its activities, carrying out calibrations
on sensors used in aerodynamic testing.

Figure 1: The TA-2.
An external six-component pyramidal balance is used for
measuring the loads acting on the model (Figure 2). The
balance was manufactured by Taller & Cooper in 1948 and
significantly modernized by CTA over the years. Model
angles may be set between ±30 degrees in pitch (α) and ±45
degrees in yaw (β). Some of the balance components have
been mechanically fixed in order to decrease random
variation in the data.
Figure 2: The external balance.
The ASA-L staff has been preparing the Low Pressure
Laboratory and the Low Force Laboratory to take part in the
Brazilian Calibration Network. Being accredited laboratories
will bring them formal recognization of competence.
Along with this series of tasks to achieve levels of services
similar to international ground test facilities, it is the
adequate estimation and assessment of the uncertainty in
measurement, which allows the comparison of test results
and contributes to the metrological reliability of the
Brazilian Aerodynamic Laboratory.
2.2. The ITA Wind Tunnel
A non-return wind tunnel is currently under design at the
Instituto Tecnológico de Aeronáutica (ITA). The support is
being provided by this project. The test section flow quality
requirements are very strict and the test-section turbulence
level is to be as low as 0.05% of the mean flow kinetic
energy. To insure that the desired turbulence level and flow
uniformity at the test section is achieved the tunnel will have
a 10:1 contraction, a honey comb and three screens with
provision for an extra one. Furthermore, the 35-meter long
facility has its inlet section, the contraction and the test
section inside a 25x10 room. The diffuser, the fan section
and the exit section are mounted outside the laboratory
room. Figure 3 shows the tunnel layout.
Figure 3: The ITA wind tunnel.
2.3. The USP wind tunnel
The Aircraft Laboratory wind tunnel facility, at the
University of São Paulo, São Carlos, is an open circuit low
speed wind tunnel with a 0.260 m high, 0.390 m wide and
0.005 m long test section. This facility was built with funds
from this project.
Studies concerning 2-D tests have been conducted at the São
Carlos wind tunnel.
Figure 4: Bi-dimensional study at the USP/São Carlos wind
tunnel.
3. METHODOLOGY
3.1. Improvement in the productivity
The commonly quoted metrics for wind tunnel productivity
are:
− Polars per hour of occupancy time [1]. Polar is used in
ground testing terninology to test a model in a determined
configuration and test condition. A polar is acquired by
taking readings for several angles of attack, in fan-on
condition;
− Polars per fan-on hour;
− Rate fan-on hour to hour of occupancy;
− Percentage of the facility down time (due to facility
problems);
− Time to model access after accomplishing a polar
acquisition (time from fan stop to hands on the model );
− Time to change the model configuration (get-the-model-
change-done –fast);
− Time of wind-on availability to obtaining data.
In order to optimize the parameters listed above, the
upgrades of the following systems are being conducted:
− Drive system (motor and fan) ;
− Velocity control;
− Data acquisiton hardware;
− Data acquisiton software; and
− Model positioning.
3.2. Improvement in the reliability
3.3. Uncertainty in the loads
The loads Fi (i = 1,...,6) act on the model during the wind
tunnel test; F1 , F2 and F3 denote forces ( drag, side and lift,
respectively) and F4 , F5 and F6 denote moments (rolling,
pitching and yawing, respectively). The external balance
measures the loads. The calibration of the balance
contributes greatly to the uncertainty of measurements in
wind tunnels.
In order to obtain a suitable model to provide aerodynamic
loads from the balance load cell measurements, a balance
calibration is performed prior to the tests. The calibration is
accomplished by applying loads to the balance through a
system of cables and pulleys named calibration cross
(Figure 5).
Seventy-three loading combinations are used. The loads F1 ,
F2 , F3 , F4 , F5 and F6 applied to the system are measured by
six load cells, which supply the readings R1 , R2 , R3 , R4 , R5
and R6 .

Wind tunnel tests supply information which is employed in

aeronautical projects for several proposals, including the
optimization of designs, the determination of the stability
charcteristics and the setting of the aerodynamic data base to
be used in flight simulation. These data will be used in the
entire aircraft development program and therefore it is
fundamental that they are reliable and that the uncertainties
in their measurement are suitably assessed.
The reliability of the tests is being improved through the:

− Improvement in data quality;

− Standardization of tests procedures;
− Implementation of documented and reliable data a)
acquisition and reduction software in LabView and C++,
respectively;
− Assessment of the uncertainty in measurement according
to standard procedures; and
− Consolidation of the Low Force and Low Pressure
Laboratories as accredited laboratories.

The TA-2 flow has being studied over the years and
improvements have being planned such as the fan changing,
the treating of the internal tunnel surface to minimize the
wall boundary layer separation and to prevent points of
leakage. Other steps may be adopted such as small
corrections in the corner vanes and the introduction of
screens.
The uncertainty in measurement must be evaluated and
documented [3]. The major error sources, in relation to the
final results, must be identified and the errors minimized. In b)
this way, the Aerodynamic Laboratory staff has conducted
several studies in order to identify the contribution of Figure 5: Loading system for balance calibration: the
uncertainty components [4] and to develop methodology of calibration cross. a) picture. b) schematic. The numbers
the assessment of the aerodynamic external balance 1,...,14 represent points of application of weights.
calibration uncertainty [5,6]. In this inovation project, this
work is to be continued, with the implementation of the A calibration curve is fitted by the least squares method to
methodology of evaluation of the uncertainty in the each set of 73 points (Fi ; R1 ,R2 ,R3 ,R4 ,R5 ,R6 )k, i = 1,...,6 [6]:
reduction system.
Fi (R) = a 1 R1 + a 2 R2 + a 3 R3 + a 4 R 4 + a 5 R5 + a 6 R6 + model which relates the forces and moments to the load
cells readings provided by six-component external balance
a 7 R + a8 R1 R2 + a 9 R1 R3 + a 10 R1 R 4 + a11R1 R5 + a12 R1 R6 + (Equation 1). The variances, the covariances and the non-
1
2

a13 R22 + a14 R2 R3 + a15 R 2 R4 + a16 R2 R5 + a 17 R2 R6 + a18 R32 linearity of the model were considered.
There are several error sources presented in the balance
+ a19 R3 R4 + a 20 R3 R5 + a 21 R3 R6 + a 22 R42 + a 23 R4 R5 + calibration. Some of them are recognizable and others may
remain unknown. The identified error sources were
a 24 R 4 R6 + a 25 R5 + a 26 R5 R6 + a 27 R6
2 2
quantified and considered in the uncertainty assessment [6].
(1) The results of the methodology applied to a specific set of
The fitting model is a linear combination of 27 (twenty calibration data points are shown in Table 1. The quantities
seven) functions of R, called the basis functions, which are: Fiapplied , i = 1,…,6, are the loads applied to the calibration
2 2
R1 , R2 , R3 , R4 , R5 , R6 , R1 , R1 R2 , R1 R3 , R1 R4 , R1 R5 , R1 R6 , R2 , cross. The quantities Fifitted correspond to the value of the
2 2
R2 R3 , R2 R4 , R2 R5 , R2 R6 , R3 , R3 R4 , R3 R5 , R3 R6 , R4 , R4 R5 , loads estimated through the curve fitting. The uncertainty in
2 2
R4 R6 , R5 , R5 R6 , R6 and has twenty seven adjustable the loads, u(Fi ), was estimated using Equation 3.
parameters a j (j =1,...,27) for F1 , twenty seven adjustable The coverage factor used to evaluate the exapanded
parameters b j for F2 , and so on, until reaching the fj uncertainty, U(Fi ), is derived from the effective degrees of
parameters for F6 . The model’s dependence on its freedom υeff , estimated from the Welch-Satterthwaite
parameters a j ,b j ,...,fj ,(j =1,...,27) is linear. The functions of formula [3].
R, are nonlinear.
The equation for the combined uncertainty of the estimation Table 1: Estimation of uncertainty in the Fi component.
of the measurand y, for N correlated input quantities and for (Unit: newton for force and newton×meter for moment).
a nonlinear model is the positive square root of [3]:

2 Fi u(F1 ) Fi Fi
 ∂y  2 ∂ y ∂y
( )
N N −1 N
u ( y) = ∑
2
  u (xi ) + 2 ∑ ∑ u xi , x j + applied fitted
 ∂ xi  i =1 j = i +1 ∂xi ∂x j
c
i =1 F1 0.39 0 0.51
(2)
F2 0.38 0 -0.20
N N  1  ∂2 y  ∂y ∂ 3 y  2
2

+ ∑∑  
∂ ∂
 +
∂ ∂ ∂ 2 u ( xi )u x j
 2
( ) F3 1.17 -2400 -2400.12
i =1 j =1  2  x x  x x x 
  i j i i j
 F4 0.29 0 -0.51
F5 0.37 -300 -299.77
Applying the law of propagation of uncertainty (2) to the F6 0.35 0 0.02
equation which represents the fitted model (1) leads to the
combined standard uncertainty of the values Fi , estimated
by the curve fitting, for any readings Ri : For the lifting force, F3 , the reported result shoud be
declared as:

u c2 (F i ) = (R1 ) u 2 (a1 ) + (R 2 ) u 2 (a 2 ) + K
2 2
“F3 = (2400.1 + 2.4) N. The reported expanded uncertainty
is stated as the standard uncertainty multiplied by the
+ ( R6 ) u 2 (a 6 ) + K + (R6 ) u 2 (a 27 ) +
2 4
coverage factor k =2.04, which for a normal distribution
+ 2[ R1 R2u (a1 , a2 ) + R1 R3 u (a1 , a3 ) + L corresponds to a coverage probability of approximately
95%.”
+ R5 R6 R62u (a 26 , a 27 )] +
+ ( a1 + 2 a 7 R1 + a 8 R2 + a 9 R3 + a10 R4 + 5. CONCLUSIONS

+ a11R5 + a12 R6 ) u (R1 ) + K 2 2 (3)

This technological inovation project, coordenated by the
first author of this paper, is a partnership among CTA,
+ ( a 6 + a12 R1 + a17 R2 + a 21R3 + a 24 R4 + EMBRAER and FAPESP. It gives support to the
+ a 26 R5 + 2 a27 R6 ) 2 u 2 (R6 ) + construction, the instrumentation and the upgrading of
wind tunnel facilities. It generates research in the areas of
1
+ (2a7 )2 u 2 ( R1 )u 2 (R1 ) + L metrological reliability, laboratory accreditation and
methodology of 2- and 3-D testing. It is worth mentioning
2
+ ( 2 R6 )2 u 2 (R6 )u 2 (a 27 )
that the project will allow EMBRAER to performe tests in
Brazil that are nowadays carried out overseas. Strategically,
this assures the confidentiality of the test results and
guarantees independence from wind tunnel facilities abroad.
4. RESULTS AND DISCUSSION
Along with this series of tasks to achieve levels of services
The uncertainty in the aerodynamic loads that act on the similar to international ground test facilities, it is the
model being tested was evaluated applying the law of adequate assessment of the uncertainty in measurement,
uncertainty propagation (Equation 2) to the mathematical which allows the comparison of test results and contributes
to the metrological reliability of the Brazilian Aerodynamic
Laboratory.
Providing reliable ground test data in shorter periods of time
is the key to helping our costumers maintain their
competitiveness in the international aeronautical market.
ACKNOWLEGEMENT
This work was supported by the Foundation for Support of
Research of the State of São Paulo (FAPESP) under grant
no. 00/13769-0.
REFERENCES
[1] M. Buckley, D. Sanford, “Low cost productivity improvements
in low speed wind tunnel testing”, 22 nd AIAA Advanced
Measurement and Ground Testing Technology Conference,
June 1998, Albuquerque, NM.
[2] F. M. Payne, “Low speed wind tunnel testing facility
requiremets: a costumer´s perspective” , AIAA-99-0306,
1999, Reno, NV.
[3] BIPM / IEC / IFCC / ISO / IUPAP / OIML, “Guide to the
Expression of Uncertainty in Measurements,” 1995.
Authors:
Dr. Olympio Achilles de Faria Mello, Centro Técnico
Aeroespacial, CTA/IAE/ASA -L, Praça Mal. Eduardo Gomes, n.º
50, São José dos Campos, São Paulo, Brasil, CEP 12228-904,
Fone: 55 12 3947 6501.
oamello@directnet.com.br
Dra. Maria Luísa Collucci da Costa Reis, Centro Técnico
Aeroespacial, CTA/IAE/ASA -L, Praça Mal. Eduardo Gomes, n.º
50, São José dos Campos, São Paulo, Brasil, CEP 12228-904,
Fone: 55 12 3947 6501.
mluisareis@yahoo.com.br
Eng.º Paulo Komatsu, Empresa Brasileira de Aeronáutica, Av.
Brigadeiro Faria Lima, 2170, São José dos Campos, São Paulo,
Brasil, CEP 12227-901, Fone 55 123927-3238.
pkomatsu@embraer.com.br
Eng.º Ricardo Sant´Anna Avim, Centro Técnico Aeroespacial,
CTA/IAE/ASA -L, Praça Mal. Eduardo Gomes, n.º 50, São José
dos Campos, São Paulo, Brasil, CEP 12228-904, Fone: 55 12 3947
6501.
ricardoalvim@iae.cta.br
Eng.º Matsuo Shisaki , Centro Técnico Aeroespacial,
CTA/IAE/ASA -L, Praça Mal. Eduardo Gomes, n.º 50, São José
dos Campos, São Paulo, Brasil, CEP 12228-904, Fone: 55 12 3947
6501.
mchisaki@ig.com.br

[4] M. L. C. C. Reis, O. Novaski, O. A. F. Mello, O. S. Sampaio,

“Evaluacion de la incertidumbre de la medicion en tunel de
viento”, [Evaluation of the Uncertainty in Measurement in a
Wind Tunnel], Información Tecnológica, La Serena, Chile,
Vol. 11, No. 6, 2000, pp. 151-160.

[5] M. L. C. C. Reis, O. A. F. Mello, S. Uyeno, “A Method for

Estimation of the Calibration Uncertainty of an External Six
Component Wind Tunnel Balancel”, AIAA Paper 2002-2793,
22nd AIAA Aerodynamic Measurements and Ground Testing
Conference, 24 - 26 June 2002, St. Louis, MO.

[6] M. L. C. C. Reis, O. A. F. Mello, S. Uyeno, O. S. Sampaio,

“Calibration Uncertainty of an External Six- Component
Wind Tunnel Balance”, AIAA Paper 2003-3884, 33rd AIAA
Fluid Dynamics Conference and Exhibit, 23 - 26 June 2003,
Orlando, Florida.