Fabrication, Testing, and 3D Comprehensive Analysis of Swept-Tip Tiltrotor Blades

Abstract

This paper covers the design, fabrication, testing, and modeling of a family of Froude-scale tiltrotor blades. They are designed with the objective of gaining a fundamental understanding of the impact of a swept tip on tiltrotor whirl flutter. The goal of this paper is to describe the development of the blades needed for this purpose. The rotor is three bladed with a diameter of 4.75 ft. The blades have a VR-7 profile, chord of 3.15 inches, and linear twist of –37° per span. The swept-tip blades have a sweep of 20° starting at 80% R. The blade properties are loosely based on the XV-15 design. A CATIA and Cubit-based high-fidelity three-dimensional (3D) finite element model is developed. It accurately represents the fabricated blade and is analyzed with X3D. Experiments in a vacuum chamber were carried out to demonstrate the structural integrity of the blades. Measured frequencies and strains were validated with X3D predictions proving the fidelity of the 3D model. Thus, even though the wind tunnel facilities were closed due to COVID-19, hover and forward flight calculations for the blade stress could be performed using the high-fidelity 3D structural model. The results prove the blades have sufficient structural integrity and stress margins to allow for wind tunnel testing.