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1
TEAM
2
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
3
SCOPE OF THE PROJECT
CAE
CAD
Profile creation of the wing using the given NACA standards.
Creation of the wing geometry
Use available data to develop CAD models for each individual component
Prepare an assembly of all components using CATIA
4
INPUT
5
DERIVED INPUT
●
Limit load : 14000 * 6= 84000 N
●
Design Load : 84000 * 1.5= 126000 N
●
Load on semi-span : 126000 / 2= 63000 N
●
Exposed wing area : 7.3625 E6 mm2
●
Pressure load on wing : 63000 / 7.3625 E6 = 8556.87 E-6 N/mm2
6
WING GEOMETRY
LEADING EDGE
ROOT CHORD
TIP CHORD
SWEEP AT ¼ CHORD
700
2400
4750
TRAILING EDGE
7
AIRFOIL
8
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.
9
DESIGN PROCEDURE
10
METHODS AND METHODOLOGY
L9
L2 L1
700
2400 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1
475
ALL DIMENSIONS IN mm
11
DESIGN PROCEDURE
CG=475/3*((700+2*870)/(700+870))
CG = 246 mm from Ltip
12
DESIGN PROCEDURE
13
SHEAR FORCE
60000
53590.65
40000 36844.85
29508.40
30000
22862.90
20000 16908.39
11644.85
10000 7072.25
3190.653190.65
0
Root 0 475 950 1425 1900 2375 2850 3325 3800 4275 TIP
4750
Wing span [Root to tip] [mm]
14
BENDING MOMENT
80000000 71809000
60000000 52341000
36527000
40000000
24039000
14548000
20000000 7727860
3248260781700 0
0
ROOT 475 950 1425 1900 2375 2850 3325 3800 4275 TIP
0 4750
Wing span [root to tip] [mm]
15
LOAD DISTRIBUTION
45% of C
Chord
RA CP RB
FS RS
25% of C a b
a=174mm
c b=148mm
62% of C
c=322mm
C=870mm
16
Shear Force Distribution:
Shear Force on Front Spar, = Load * b/c
At Section 1, SFFS = 3190.65 * (148/322)
SFFS = 1465.974 N
17
Bending Moment Distribution:
Moment is distributed in same ratio as that of the Shear force.
18
SHEAR FORCE & BENDING MOMENT
Front Spar
Rear Spar
19
MATERIAL
Material : AA 2024-T6
Ultimate tensile strength, σ : 427 MPa
Shear strength : 283MPa
Density : 2.79 E-6 kg/mm3
Young's Modulus, E : 72400 Mpa
Poisson's Ratio : 0.33
[Aluminum Association, Inc]. [7]
20
Moment of Inertia:
21
MOMENT OF INERTIA
Front Spar
Rear Spar
22
TORSION
24
Torque
Shear Flow
25
TORQUE DIAGRAM
11857039.54
12000000 Torque diagram for the wing span
10000000
8689789.08
8000000
Torque [N-mm]
6187429.48
6000000
4252608.34
4000000 2795550.39
1734041.9
2000000 992888.78
506210.31
212789.99
58285.91 0
0
ROOT 475 950 1425 1900 2375 2850 3325 3800 4275 TIP
0 4750
Wing span [root to tip] [mm]
26
SHEAR FORCE DUE TO TORSION
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
27
SHEAR FORCE DUE TO TORSION
Front Spar
Rear Spar
28
TOTAL SHEAR FORCE
Front Spar
Rear Spar
29
WEB THICKNESS
Thickness of the Web can be calculated from the following formula,
Front Spar
Rear Spar
31
FLANGE
32
FLANGE
Front Spar
Rear Spar
33
MASS CALCULATIONS
AFS = Aflange + Aweb
AFS = 14.09 + 5.53 = 19.62 mm2
34
MASS CALCULATIONS
14
13.67
13.49 13.50
13.5
13.32 13.33 13.34
11.5
62 63 64 Rear
65 spar
66 position
67in % 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
35
BUCKLING
To Check whether the web fails under shear buckling.
Condition: Shear stressinduced< Buckling stress (safe design)
The thickness calculation is based on iterations,
●
Finduced= q / tweb
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
37
Front Spar
Rear Spar
38
MASS CALCULATION
From buckling calculation the total mass of the spars is 16.14 kg.
●
To decrease the mass, one more iteration has been carried out.
●
39
ITERATION-2
●
For optimum Rib spacing, (a/b) ratio >= 1
Rib no. Rib dist. From root Spar heights (a/b) ratio Web thickness Web volume
FS RS FS RS K from graph FS RS FS RS
[mm] [mm] [mm] FS RS [mm] [mm] 3
[mm ]
3
[mm ]
0 TIP4750 64.49 54.05 0 0.00 - - - -
1 4440 81.97 68.4 3.78 4.53 5.10 5.00 0.22 0.2 5590.56 4240.8
2 4110 100.58 83.67 3.28 3.94 5.17 5.08 0.34 0.3 11285.3 8283.53
3 3780 119.19 98.94 2.77 3.34 5.30 5.15 0.44 0.39 17306.53 12734.09
4 3450 137.8 114.22 2.39 2.89 5.50 5.20 0.53 0.48 24101.05 18091.81
5 3120 156.41 129.49 2.11 2.55 5.75 5.40 0.64 0.57 33033.37 24356.69
6 2790 175.02 144.76 1.89 2.28 6.00 5.60 0.74 0.67 42739.15 32006.44
7 2470 193.06 159.57 1.66 2.01 6.30 5.80 0.84 0.76 51894.8 38807.18
8 2150 211.11 174.38 1.52 1.84 6.55 6.20 0.94 0.84 63500.68 46872.81
9 1830 229.15 189.19 1.40 1.69 6.90 6.25 1.03 0.94 75528.17 56907.75
10 1520 246.63 203.53 1.26 1.52 7.25 6.55 1.12 1.02 85630.63 64357.45
11 1210 264.11 217.88 1.17 1.42 7.60 6.80 1.2 1.1 98250.04 74297.42
12 900 281.59 232.23 1.10 1.33 7.80 7.00 1.31 1.19 114355.32 85668.54
13 600 298.51 246.11 1.00 1.22 8.20 7.35 1.39 1.26 124479.09 93029.96
14 300 315.43 259.99 1.05 1.15 8.00 7.60 1.51 1.35 142888.88 105297.57
15 Root 0 332.35 273.88 1.11 1.10 7.80 7.80 1.63 1.43 162519.15 117494.52
Total volume 1053102.72 782446.56
Web volume 1835549.28
40
WEIGHT CALCULATION
●
Finally mass of the spars reduced by 0.89 kg when compared to 1st iteration.
●
These dimensions are taken for modelling
41
RESULTS AND DISCUSSION
1.63
1.60 1.51
1.39
1.31
1.20
1.20 1.12 ACTUAL
1.03 FROM BUCKLING
0.94
0.84
0.80 0.74
0.64
0.53
0.44
0.39 0.36
0.40 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
0.00
Root 0 300 600 900 1210 1520 FROM
1830 2150ROOT TO3120
2470 2790 TIP3450
[mm]3780 4110 4440 4750
42
WEB THICKNESS FOR REAR SPAR
2.00
THICKNESS OF WEB[mm]
1.60
1.43
1.35
1.26
1.19
1.20 1.10 ACTUAL
1.02 FROM BUCKLING
0.94
0.84
0.76
0.80
0.67
0.57
0.52 0.49 0.46 0.48
0.43 0.39 0.39
0.36
0.40 0.33 0.30 0.30
0.26 0.23 0.20 0.20
0.16 0.13 0.10 0.06
0.00
Root 0 300 600 900 1210 1520 1830 FROM ROOT
2150 2470 TO TIP
2790 3120 3450 3780 4110 4440 4750
43
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.
44
SCOPE FOR FURTHER WORK
●
Spar position can be optimized based on buckling calculations.
●
Further optimization of Rib is possible.
--Varying number of Ribs and spacing of Ribs.
●
Use of other materials for the design of spars can be thought of.
●
Detail stress analysis of individual components and its validation with
calculations can be carried out.
45
CAD
46
CAD MODELING OF THE WING SPAR
47
1. Generation of the profiles at the root and tip using the NACA profiles.
48
●
INCORPORATING THE LEADING EDGE RADIUS AS
SPECIFIED IN THE PROFILE STANDARD.
1.Giving the slope in the sketcher 2.Creating the arc of the
mode required dimension coming
out of sketcher.
49
●
Using the connect curve option to join the leading edge radius and the aerofoil
profile.
●
Create the surface using multi section surface option.
50
INTERSECTION OF THE PROFILES
●
Creating the planes at the four sections at ½, ¼, ¾ of the span of the wing.
●
Intersecting the lofted surface on the planes creating unique sketches on them.
51
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.
52
CREATE THE SURFACE USING MULTI SECTION
SURFACE OPTION
By considering the profiles generated with angle of attack at different sections,
the wing surface is created using multi-section surface option.
Thus the surface is created as per the requirements incorporating all the necessary data.
53
CREATION OF REFERENCE AEROFOIL SECTIONS
●
15 planes are created at rib positions along the wing span.
●
The intersections created are used as the reference for the creation of the spar.
54
CONSIDERATIONS MADE
DURING THE DESIGN OF SPAR
ELEMENTS
●
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.
55
DESIGNING OF SPAR ON
MANUFACTURING BASIS
➢
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.
56
CROSS SECTION SPAR
Rib no. Dist. From root Flange Width Skin Area Available area Flange Thickness Effective Flange area Web thickness
From root (mm) (mm) (mm2) (mm2) (mm) (mm2) (mm)
1 Root 0 70 220 266.94 3.81 266.94 1.63
2 300 70 220 215 3.07 215 1.63
3 600 70 220 175 2.5 175 1.63
4 900 65 210 150 2.31 150 1.29
5 1210 65 155.2 144.9 2.23 144.9 1.29
6 1520 60 147.2 116.4 2 120 1.29
7 1830 60 147.2 86.4 2 120 1.29
8 2150 55 139.2 60.4 2 110 0.91
9 2470 50 88.8 55.6 2 100 0.91
10 2790 45 82.8 36.1 2 90 0.91
11 3120 40 76.8 16.6 2 80 0.64
12 3450 35 70.8 -0.4 2 70 0.64
13 3780 30 64.8 -12.4 2 60 0.64
14 4110 30 64.8 -19.9 2 60 0.64
15 4440 30 64.8 -24.9 2 60 0.64
16 NO RIB 4750
58
REAR SPAR DIMENSIONS
Rib no. Dist. From root Flange Width Skin Area Available area Flange Thickness Effective Flange area Web thickness
From root (mm) (mm) (mm2) (mm2) (mm) (mm2) (mm)
1 Root 0 90 260 415.01 4.61 415.01 1.45
2 300 90 260 340 3.78 340 1.45
3 600 80 240 295 3.69 295 1.45
4 900 75 230 257.5 3.43 257.5 1.15
5 1210 70 204 223 3.19 223 1.15
6 1520 65 194 180.5 2.78 180.5 1.15
7 1830 60 184 138 2.3 138 1.15
8 2150 55 174 100.5 2 110 0.91
9 2470 50 148 73.5 2 100 0.91
10 2790 45 138 48.5 2 90 0.91
11 3120 40 128 21 2 80 0.64
12 3450 35 118 4 2 70 0.64
13 3780 30 108 -19 2 60 0.64
14 4110 30 108 -36.5 2 60 0.64
15 4440 30 108 -43 2 60 0.64
16 NO RIB 4750
59
CREATION OF THE SPAR SECTIONS
1. Two T sections for the flange, and web section for the front spar.
2. Two L sections for the flange, and web section for the rear spar.
61
CRIMP HOLES OR LIGHTENING HOLES
The lightening holes are made in the element in order to reduce the weight of the
element. the crimp holes are made to the web element of the spar. These holes
provided in between the two successive rib locations.
62
SPAR WITH LIGHTENING HOLES
63
REPRESENTATION OF RIVET HOLES
64
FINAL SPAR ASSEMBLY
65
BIBLIOGRAPHY
&
CADES Library.
66
THANK YOU
67