Abstract
A design procedure for the synthesis of active camber morphing wing devices is proposed. A topology optimization initially defines the internal structure that is further enhanced by structural size and shape optimizations, and these optimizations are based on the distributed compliance concept. The size optimization enables the adaption of the topology solution to other materials and geometries while refining the topology solution to improve the shape quality of the skin deformation. Then, the structural shape optimization enables the reduction of the stress peaks inside the compliant structure and the finalization of the details to obtain a solution that is closer to the manufacturing process stage. The proposed methodology is used in the design of an adaptive droop nose to be installed on a reference regional aircraft, and two different design applications are considered. The first application is the validation of the procedure at the full–scale level using a superelastic material for the internal structure. The second application is the design of a corresponding 3D–printed prototype, in which both geometry and material changes are considered, for experimental validation. The results show satisfactory shape quality and the achievement of structural feasibility. The experimental functional test of the scaled prototype demonstrates the effectiveness of the adopted morphing solution.
Highlights
Morphing is a solution that can be used to improve the global performances of modern aircraft by enabling the achievement of higher aerodynamic efficiency by adapting the wing shape during the mission
Structural shape optimization works based on high–fidelity models, can consider structural details that are not included in the models that are used in the previous levels, and enables the solution to get close to the level of detail requested for manufacturing
According to the optimization problem definition, and since large deformations are expected inside the compliant structures, two different kind of static non-linear analyses can be conducted: (a) analysis of the model that corresponds to the kinematic requirement and to the least–square error (LSE) computation when the compliant structure is actuated and the skin is subjected to the aerodynamic loads that are related to the morphing configuration; and (b) analysis of the model that corresponds to the structural requirement and to the strain energy (SE) computation when the actuation point is kept fixed and the skin is subjected to the aerodynamic loads that are related to all flight conditions considered in the structural design
Summary
Morphing is a solution that can be used to improve the global performances of modern aircraft by enabling the achievement of higher aerodynamic efficiency by adapting the wing shape during the mission. Size and shape optimizations are linked to the two–level optimization procedure, as described above They combines different design capabilities and takes into account additional constraints, not considered in the first two levels, such as the material, geometry and manufacturing requirements. The shape optimization reduces the local stress concentrations inside the compliant structure, and a detailed finite element model (FEM) is adopted, which can be converted into a corresponding CAD model that is ready to be manufactured. This methodology is applied in the EU–funded Clean Sky 2 REG-IADP AG2 project, where a reference regional aircraft equipped with different morphing devices, such as a droop nose, a flap and a winglet, is considered.
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