Design of Front and Rear Spars for The

Trainer Aircraft Wing.

TEAM
Team Members :
CAE

Akshay A. Pradeep S. Shet

CAD

Pavan Kumar N. R. Raghunandan M. Lakshmana H. B. Chetan A. V.

Guide Co-ordinator

: :

Mr. H. N. Athavale Mr. Umanath Nayak

OBJECTIVE

CAD

To generate the CAD model of wing using the available data and
prepare the assembly of all components

CAE

Determine the Spar locations with respect to chord length.

Determine the dimensions for flange and web of the spars. Estimate the number of ribs and their positioning

SCOPE OF THE PROJECT

CAE

Estimation of spar position.

Dimension calculations of front and rear spars. Calculations for number of ribs and their positions. CAD Profile creation of the wing using the given NACA standards. Creation of the wing geometry Use available data to develop CAD models for each individual component

Prepare an assembly of all components using CATIA

INPUT
Root chord : 2400 mm Tip chord : 700 mm Semi Span length : 5500 mm Exposed Span : 4750 mm Airfoil (root) : NACA 64A1215 (tip) : NACA 64A1210 Aircraft weight : 14000 N Lift Load : 6g Design Factor : 1.5 Given Spar Position(in % of chord length) Front Spar : 18-25 Rear Spar : 62-70

DERIVED INPUT

Limit load
Design Load Load on semi-span Exposed wing area

: 14000 * 6= 84000 N
: 84000 * 1.5= 126000 N : 126000 / 2= 63000 N : 7.3625 E6 mm2 : 63000 / 7.3625 E6 = 8556.87 E-6 N/mm2

Pressure load on wing

WING GEOMETRY

LEADING EDGE

ROOT CHORD

SWEEP AT CHORD

4750

Top View [RH]

TIP CHORD

AIRFOIL

Generate the aerofoil section using the Coordinates of NACA 64A1215 and NACA 64A1210.

[source : http://www.pdas.com/sections6a.htm]

Generate the CAD model of the wing using CATIA- V5.

Aerofoil at Tip NACA 64A1210

Aerofoil at Root NACA 64A1215

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DESIGN PROCEDURE

Calculation of the Shear force, Bending moment & Torsion for the given load. Calculation of load distribution between the front and rear spar. Estimation of spar positions.

Generation of CAD Model and Drafting.

DESIGN PROCEDURE
Divide the wing area into number of divisions.
Calculate the chord length at each section. Determine the C.G of each area. Calculate the shear force, bending moment and Torque at the respective sections.

Shear force =pressure*area.

Bending moment=shear force*CG distance. Torque = Shear force*Distance b/w CG and CP.

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METHODS AND METHODOLOGY

L9 L2 L1

700

2400

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

475

ALL DIMENSIONS IN mm

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DESIGN PROCEDURE

Chord Length, L1= Lroot-((Lroot-Ltip) / S) * x At section 2, L1 = 2400-((2400-700)/4750)*4275 Lroot L1 = 870 mm

L1 x
A1

Ltip

Area of Trapezium, A1 = 0.5*(L1+Ltip)*h A1 = 0.5*(870+700)*475 A1 = 373 E3 mm2 CG of Trapezoid Section = h/3*((Ltip+2L1)/(Ltip+L1)) CG=475/3*((700+2*870)/(700+870)) CG = 246 mm from Ltip

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DESIGN PROCEDURE
Limit load = 84000 N Design Load = Limit Load*Design factor Design load on wing, = 84000*1.5 = 1,26,000 N Design load on semi-span wing, = 63000 N pressure load on wing [P] = 8556.87 E-6 N/mm2

Load At Section 2, = P2+P1 = P*A2+P1 = 8557 E-6 * 453625 + 3190.65 = 3881.6 + 3190.65 = 7072.25 N Bending Moment At Section 2, M2 = P2 * CG2 + P1 * (CG1 + L2) M2 = 3881.6 * 230 + 3190.65 * (229 + 475) M2 = 3248260 N-mm
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SHEAR FORCE

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BENDING MOMENT

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LOAD DISTRIBUTION
Centre of Pressure, CP = 45% of Chord Length (C) from LE [870mm] Front Spar Position = 25% of C from LE [217.5mm] Rear Spar Position = 62% of C from LE [539.4mm] [1]

45% of C

Chord
RA

CP
a c
62% of C

RB

25% of C

FS

RS a=174mm b=148mm c=322mm C=870mm

Chord Length 'C'

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Shear Force Distribution:

Shear Force on Front Spar, = Load * b/c At Section 1, SFFS = 3190.65 * (148/322) SFFS = 1465.974 N Shear Force on Rear Spar SFRS = 3190.65 - 1465.974 SFRS = 1724.676 N SF on Front Spar SF on Rear Spar = 45.9% of total load = 54.1% of total load

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Bending Moment Distribution:

Moment is distributed in same ratio as that of the Shear force. Bending Moment on Front Spar, MFS = 0.459 * 781700 MFS = 359159 N-mm Bending Moment on Rear Spar, MRS = 781700 - 359159 MRS = 422541N-mm

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SHEAR FORCE & BENDING MOMENT

Front Spar

Rear Spar

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MATERIAL
Material Ultimate tensile strength, Shear strength Density Young's Modulus, E Poisson's Ratio : AA 2024-T6 : 427 MPa : 283MPa : 2.79 E-6 kg/mm3 : 72400 Mpa : 0.33
[Aluminum Association, Inc]. [7]

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Moment of Inertia: I = M*y/

Where, M y I = Moment of Inertia, in mm4 = Bending Moment, in N-mm = distance b/w neutral axis to top surface, in mm = Tensile strength, in MPa

Moment of Inertia on Front Spar, IFS IFS Moment of Inertia on Rear Spar, IRS IRS

= 359159 * 52.8 / 427 = 44412 mm4 = 422541 * 43.44 / 427 = 42987 mm4

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MOMENT OF INERTIA

Front Spar

Rear Spar

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TORSION

Area of Torque Box, A1 = 30980.3 mm2 CG of Torque Box = 165 mm From Rear spar Distance Between CG & CP = 18.268 mm Torque, T = Load*d = 3190.65 * 18.268 T = 58286 N-mm Shear flow, q1 = T/(2*A1) [2] q1 = 58286 / (2 * 30980.3) q1 = 0.941 N/mm
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CG OF TORQUE BOX

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Torque

Shear Flow

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TORQUE DIAGRAM

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SHEAR FORCE DUE TO TORSION

Shear force (SF) on Front Spar SFFS = q * hFS SFFS = 0.941*105.6 = 99.34 N Total SF on FS = 1465.974+99.34 = 1565.313 N

On Rear Spar SFRS = q*hRS SFRS = 0.941*86.88 SFRS = 81.729 N Total SF on RS = 1724.676+81.729 = 1806.405 N

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SHEAR FORCE DUE TO TORSION

Front Spar

Rear Spar

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TOTAL SHEAR FORCE

Front Spar

Rear Spar

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WEB THICKNESS
Thickness of the Web can be calculated from the following formula,

Where,

shear strength= SFFS / A web

shear strength= Shear strength of the material AA 2024-T6 in MPa

A web = Area of the web = (height * thickness) in mm

283 = 1565.313 / (105.602 * t web) t web = 0.052 mm Area of the web = height * thickness = 105.602 * 0.052 A web = 5.531 mm2 Moment of Inertia of Web: Moment of Inertia of a rectangular section web is given by, I web = t web * (hFS)3 / 12 I web = 0.052 * (105.602)3 / 12 I web = 5140.175 mm4
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WEB

Front Spar

Rear Spar

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FLANGE

MOIflange = MOIFront Spar - MOIWeb I flange = IFS - Iweb = 44411 - 5140.175 I flange= 39270.825 mm4 Also Moment of Inertia of the flange is given by, I flange = Aflange * (yFS)2 Where, Iflange = Moment of Inertia of flange in mm4 yFS= height from neutral axis to top surface of the flange in mm Hence, Aflange = Iflange / (yFS)2 = 39270.825 / (52.801)2

Aflange = 14.086 mm2

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FLANGE

Front Spar

Rear Spar

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MASS CALCULATIONS
AFS = Aflange + Aweb AFS = 14.09 + 5.53 = 19.62 mm2 VFS = AFS * 475 = 19.62 * 475 VFS = 9318.3 mm3

Mass = Density * Total Volume = 2.78 E-6 * 4218551.12

Mass = 11.73 kg

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MASS CALCULATIONS

Hence, from the Calculations it is found that (25% - 62%) combination of Spar Position was found suitable. The Mass of this combination is 11.73 Kg which is least than any other combinations
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Front spar position

BUCKLING
To Check whether the web fails under shear buckling. Condition: Shear stressinduced< Buckling stress (safe design)

The thickness calculation is based on iterations,

Finduced= q / tweb
Fcritical = k*E*(tweb/ b)2
where, q = shear flow, in N/mm E = Young's Modulus, in MPa b = height of spar, in mm
[4]

tweb= web thickness, in mm

k = shear buckling coefficient from graph
[4]

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BUCKLING CALCULATIONS
ITERATION 1. RIB SPACING FOR EQUAL DISTANCE OF 475mm
Web thickness's of front spar at section 1 is as follows, Finduced = q1 / t web------------ (1) = 0.941 / 0.052 Finduced = 18.09 N/mm2 Fallowable = K * E * (t web / b)2-----------(2) 18.09 = 5 * 72400 * (t web / 105.602)2 The value calculated for tweb is re substituted in Eqn.(1) and this loop will continue till we get equal consecutive thickness. Hence, the thickness of the web is 0.30 mm at section 1. Same calculations were repeated for all sections of front spar to optimize the web thickness

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Front Spar

Rear Spar

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MASS CALCULATION

Web design is safe under buckling. From buckling calculation the total mass of the spars is 16.14 kg. By this, mass of the spars got increased by 4.41 kg. To decrease the mass, one more iteration has been carried out.

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ITERATION-2
Rib no. Rib dist. From root [mm] TIP4750 4440 4110 3780 3450 3120 2790 2470 2150 1830 1520 1210 900 600 300 Root 0

For optimum Rib spacing, (a/b) ratio >= 1

Spar heights FS RS (a/b) ratio FS RS 0 3.78 3.28 2.77 2.39 2.11 1.89 1.66 1.52 1.40 1.26 1.17 1.10 1.00 1.05 1.11 0.00 4.53 3.94 3.34 2.89 2.55 2.28 2.01 1.84 1.69 1.52 1.42 1.33 1.22 1.15 1.10 Web thickness FS RS Web volume FS RS 3 3 [mm ] [mm ]

K from graph

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

[mm] 64.49 81.97 100.58 119.19 137.8 156.41 175.02 193.06 211.11 229.15 246.63 264.11 281.59 298.51 315.43 332.35

[mm] 54.05 68.4 83.67 98.94 114.22 129.49 144.76 159.57 174.38 189.19 203.53 217.88 232.23 246.11 259.99 273.88

FS
5.10 5.17 5.30 5.50 5.75 6.00 6.30 6.55 6.90 7.25 7.60 7.80 8.20 8.00 7.80

RS
5.00 5.08 5.15 5.20 5.40 5.60 5.80 6.20 6.25 6.55 6.80 7.00 7.35 7.60 7.80

[mm] [mm] 0.22 0.2 5590.56 4240.8 0.34 0.3 11285.3 8283.53 0.44 0.39 17306.53 12734.09 0.53 0.48 24101.05 18091.81 0.64 0.57 33033.37 24356.69 0.74 0.67 42739.15 32006.44 0.84 0.76 51894.8 38807.18 0.94 0.84 63500.68 46872.81 1.03 0.94 75528.17 56907.75 1.12 1.02 85630.63 64357.45 1.2 1.1 98250.04 74297.42 1.31 1.19 114355.32 85668.54 1.39 1.26 124479.09 93029.96 1.51 1.35 142888.88 105297.57 1.63 1.43 162519.15 117494.52 Total volume 1053102.72 782446.56 Web volume 1835549.28

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WEIGHT CALCULATION

Finally mass of the spars reduced by 0.89 kg when compared to 1st iteration.

These dimensions are taken for modelling

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RESULTS AND DISCUSSION

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43

CONCLUSION

Front Spar positioning is estimated to 25% and Rear Spar to 62% of the Chord Length.

Flange and web dimensions are calculated and suitable changes in dimensions are incorporated from manufacturing point of view.

Number of Ribs and their positioning for the prevention of bending and buckling of Spars is calculated.

Mass of the spars calculated from iterations is 15.25 kg. The Detail drawings for the front and rear spars are provided using CATIA V5.

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SCOPE FOR FURTHER WORK

Spar position can be optimized based on buckling calculations.

Further optimization of Rib is possible. --Varying number of Ribs and spacing of Ribs.

Use of other materials for the design of spars can be thought of.

Detail stress analysis of individual components and its validation with calculations can be carried out.

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CAD

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CAD MODELING OF THE WING SPAR

Taking values from NACA Standards At Root: Profile: NACA 64A1215. Leading Edge radius = 1.556% c. Slope of mean line at leading edge = 0.0842.

At Tip:

Profile: NACA 64A1210. Leading Edge radius = 0.701% c. Slope of mean line at leading edge = 0.0842.

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1. Generation of the profiles at the root and tip using the NACA profiles.

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INCORPORATING THE LEADING EDGE RADIUS AS SPECIFIED IN THE PROFILE STANDARD.

2.Creating the arc of the required dimension coming out of sketcher.

1.Giving the slope in the sketcher mode

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Using the connect curve option to join the leading edge radius and the aerofoil profile.

Create the surface using multi section surface option.

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INTERSECTION OF THE PROFILES

Creating the planes at the four sections at , , of the span of the wing. Intersecting the lofted surface on the planes creating unique sketches on them.

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ANGLE OF ATTACK

Create a point at the quarter chord and draw a line for reference. Rotate the intersected profiles as 0.60 at the quarter, 1.10 at mid span, 1.60 at three

fourths and 20 at the tip.

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CREATE THE SURFACE USING MULTI SECTION SURFACE OPTION

By considering the profiles generated with angle of attack at different sections, the wing surface is created using multi-section surface option.

Thus the surface is created as per the requirements incorporating all the necessary data.

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CREATION OF REFERENCE AEROFOIL SECTIONS

15 planes are created at rib positions along the wing span. The intersections created are used as the reference for the creation of the spar.

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CONSIDERATIONS MADE DURING THE DESIGN OF SPAR ELEMENTS

The maintenance of the nose box is made easy. The front spar is I section. The rear spar is C section. Minimum distance required for a single row riveting is kept as 15 mm.

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DESIGNING OF SPAR ON MANUFACTURING BASIS

The front spar is placed at 25% of chord length from leading edge.
The rear spar is placed at 62% of chord length from leading edge. Thicknesses of the flanges and webs are different. The flanges are made of T-sections and L- sections. The webs are made with sheet metal. The thicknesses are optimized based on the availability of the standard gages of sheet metal. The final assembly of elements can be fastened with rivets.

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CROSS SECTION SPAR

Skin area, As = (b +2*20*ts) mm2 Effective flange area = (Af- As)/2

where , b= flange width in mm ts =skin thickness in mm Af =designed flange area in mm2 Web thickness is altered as per the availability of sheet metal gages.
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FRONT SPAR DIMENSIONS

Rib no. Dist. From root Flange Width From root (mm) (mm) 1 Root 0 70 2 300 70 3 600 70 4 900 65 5 1210 65 6 1520 60 7 1830 60 8 2150 55 9 2470 50 10 2790 45 11 3120 40 12 3450 35 13 3780 30 14 4110 30 15 4440 30 16 NO RIB 4750 Skin Area (mm2) 220 220 220 210 155.2 147.2 147.2 139.2 88.8 82.8 76.8 70.8 64.8 64.8 64.8 Available area Flange Thickness Effective Flange area Web thickness (mm2) (mm) (mm2) (mm) 266.94 3.81 266.94 1.63 215 3.07 215 1.63 175 2.5 175 1.63 150 2.31 150 1.29 144.9 2.23 144.9 1.29 116.4 2 120 1.29 86.4 2 120 1.29 60.4 2 110 0.91 55.6 2 100 0.91 36.1 2 90 0.91 16.6 2 80 0.64 -0.4 2 70 0.64 -12.4 2 60 0.64 -19.9 2 60 0.64 -24.9 2 60 0.64

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REAR SPAR DIMENSIONS

Rib no. Dist. From root Flange Width Skin Area Available area Flange Thickness Effective Flange area Web thickness From root (mm) (mm) (mm2) (mm2) (mm) (mm2) (mm) 1 Root 0 90 260 415.01 4.61 415.01 1.45 2 300 90 260 340 3.78 340 1.45 3 600 80 240 295 3.69 295 1.45 4 900 75 230 257.5 3.43 257.5 1.15 5 1210 70 204 223 3.19 223 1.15 6 1520 65 194 180.5 2.78 180.5 1.15 7 1830 60 184 138 2.3 138 1.15 8 2150 55 174 100.5 2 110 0.91 9 2470 50 148 73.5 2 100 0.91 10 2790 45 138 48.5 2 90 0.91 11 3120 40 128 21 2 80 0.64 12 3450 35 118 4 2 70 0.64 13 3780 30 108 -19 2 60 0.64 14 4110 30 108 -36.5 2 60 0.64 15 4440 30 108 -43 2 60 0.64 16 NO RIB 4750

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CREATION OF THE SPAR SECTIONS

1. Two T sections for the flange, and web section for the front spar. 2. Two L sections for the flange, and web section for the rear spar.

FRONT SPAR

REAR SPAR

FULL PROFILE
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GENERATING SPAR USING DIFFERENT SECTIONS

61

CRIMP HOLES OR LIGHTENING HOLES

The lightening holes are made in the element in order to reduce the weight of the element. the crimp holes are made to the web element of the spar. These holes provided in between the two successive rib locations.

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SPAR WITH LIGHTENING HOLES

63

REPRESENTATION OF RIVET HOLES

64

FINAL SPAR ASSEMBLY

65

BIBLIOGRAPHY
1] Abbot & Albert,'Theory of wing sections',Dover publication,1949. 2] David J. Perry,'Aircraft structures',Mc-Graw Hill publication,1950. 3] E. F. Bruhn,'Analysis and design of flight vehicle structures',1973. 4] Michael C. Y. Niu, 'Airframe Stress Analysis and Sizing', 2001. 5] Michael C. Y. Niu, 'Airframe structural design', Conmilit press Ltd., 1989. 6] Kuethe and Schetzer, 'Foundations of Aerodynamics', 2nd Edition, John Wiley

and Sons, New York, 1959.

7] ASM Material Data Sheet 8] MIL Handbook. & CADES Library.
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