A Road Map to the Structural Optimization of a Type-C Composite UAV

Abstract

The present paper investigates the design process and the dimensioning of a tailless type-C composite sandwich unmanned aerial vehicle (UAV). The objective is to investigate an innovative aircraft configuration which exceeds the standard approach of ribs and spars and replaces them with a sandwich structure for future unmanned aerial systems. The necessity of carbon fiber-reinforced materials arose due to the weight constraint of a Class C UAV, i.e., the whole vehicle must be under 25 kg, which limits the mass of the structure to 9 kg. The structural design of composite structures differs from the one of traditional isotropic structures. The number of holes should be limited, as drilling down the composite aerostructure would conclude to the generation of delaminations. In addition, the joints between sections with different thicknesses could lead to stress concentrations and disbands. Therefore, the present report is crucial for the continuance of the present project as it has contributed both to the structural design and assessment of the UAV. This work focusses on the computation of loads, the process of structural sizing through a multi-disciplinary optimization approach, and the simulation-based structural proof. Particular attention is paid to the specifically developed semi-analytical method for predicting the aero-elastic load. Based on the detailed finite element model of the global structure, the applicability of the minimum number of bolts as a major structural joining variant is proven. The design process from single components to the assembly of the overall aircraft results in the realization of the demonstrator structure.