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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
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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
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DERIVED INPUT
: 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
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WING GEOMETRY
LEADING EDGE
ROOT CHORD
SWEEP AT CHORD
4750
TIP CHORD
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AIRFOIL
Generate the aerofoil section using the Coordinates of NACA 64A1215 and NACA 64A1210.
[source : http://www.pdas.com/sections6a.htm]
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.
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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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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 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
L1 x
A1
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
63000.00
60000.00
53590.65
BENDING MOMENT
123020000
95259000 71809000 52341000 36527000 24039000 14548000 7727860 3248260 781700 475 950 1425 1900 2375 2850
ROO T 0
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
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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 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
Torque [N-mm]
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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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Front Spar
Rear Spar
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Front Spar
Rear Spar
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WEB THICKNESS
Thickness of the Web can be calculated from the following formula,
shear strength=
shear strength=
Where,
SFFS / A web
Shear strength of the material AA 2024-T6 in MPa
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
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MASS CALCULATIONS
13.75 13.50
13.32 13.49 13.33 13.18 13.02 12.87 12.72 12.59 12.51 13.67 13.50 13.34 13.18 13.02 12.87 12.77 12.68
13.25 13.00
13.02 12.88 12.75 12.62 12.50 12.39 12.27 12.16 12.05 11.95 11.84 12.50 12.38 12.26 12.15 12.03 11.92 11.81 12.62 12.49 12.37 12.25 12.13 12.01 11.89 12.74 12.61 12.49 12.36 12.23 12.11 11.98 12.88 12.74 12.61 12.48 12.34 12.21 12.08
18 19 20 21 22 23 24 25
63
64
65
66
67
68
69
70
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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Mass [kg]
BUCKLING
To Check whether the web fails under shear buckling. Condition: Shear stressinduced< Buckling stress (safe design) The thickness calculation is based on iterations,
[4]
[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
K from graph
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
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
[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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THICKNESS OF W EB[mm]
1.60
1.20
0.80
0.40
0.44 0.390.36 0.34 0.32 0.34 0.29 0.27 0.25 0.22 0.22 0.20 0.17 0.15 0.12 0.10 0.07 0.04
300 600 900 1210 1520 1830 2150 2470 2790 3120 3450 3780 4110 4440 4750
0.00
Root 0
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THICKNESS OF WEB[mm]
1.60
1.43 1.35 1.26 1.19 1.10 1.02 0.94 0.84
1.20
0.80
0.52 0.49 0.46
0.57 0.43 0.48 0.39 0.36 0.33 0.39 0.30 0.26 0.30 0.23 0.20 0.16 0.13 0.20 0.10
4110
0.40
0.06
4440 4750
0.00
Root 0 300 600 900 1210 1520 1830 2150 2470 2790 3120 3450 3780
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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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CAD
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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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Using the connect curve option to join the leading edge radius and the aerofoil profile.
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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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Thus the surface is created as per the requirements incorporating all the necessary data.
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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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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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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
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FULL PROFILE
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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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THANK YOU
CADES Digitech Pvt. Ltd.
Tel: +91 80 4193 9000 Fax: +91 80 4193 9099 URL: www.cadestech.com
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