ADDITIVE MANUFACTURING PROCESS-INDUCED WING SKIN DEFORMATION AND EFFECTS ON AERODYNAMIC PERFORMANCE

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

The objective of this study is to characterize the trade space for the structural design of small uncrewed aerial vehicle wings fabricated using Material Extrusion Additive Manufacturing, specifically the trade-off between maintaining the wing external shape while minimizing its internal structure. Beam bending analysis shows that the structural requirements associated with flight loads are easily met with a single perimeter extrusion monocoque construction, however this approach leads to large, unsupported, thin-walled structures that can deform during the build process, creating a potential need for additional structure to maintain wing shape. To characterize the relationship between structure/weight and wing deformation, wing sections were fabricated with varying internal structures for two airfoil shapes. Weight and 3-D laser measurements were taken of the printed parts to capture the final as-built geometry. The as-built geometries were then compared to the as-designed geometries to quantify the deformation, and a coupled viscous-inviscid flow solver was used to determine the aerodynamic effects. The results indicate that while significant aerodynamic performance penalties exist for the monocoque construction, a small amount of well-placed internal structure provides sufficient improvement at minimal weight penalty. Results also showed that less internal structure is required to minimize deformation for an airfoil with larger initial curvature.

Original languageEnglish (US)
Title of host publicationAdvanced Materials
Subtitle of host publicationDesign, Processing, Characterization and Applications; Advances in Aerospace Technology
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791886656
DOIs
StatePublished - 2022
EventASME 2022 International Mechanical Engineering Congress and Exposition, IMECE 2022 - Columbus, United States
Duration: Oct 30 2022Nov 3 2022

Publication series

NameASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)
Volume3

Conference

ConferenceASME 2022 International Mechanical Engineering Congress and Exposition, IMECE 2022
Country/TerritoryUnited States
CityColumbus
Period10/30/2211/3/22

All Science Journal Classification (ASJC) codes

  • Mechanical Engineering

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