Modeling, Structural & CFD Analysis and Optimization of UAV

Modeling, Structural & CFD Analysis and Optimization of UAV
Dr Lazaros Tsioraklidis Department of Unified Engineering InterFEA Engineering, Tantalou 7 Thessaloniki GREECE
Next Generation tools for UAVs
The current paper present the usages of Hyperworks on the design of New ages Aerostructures as UAV's.
Copyright InterFEA Engineering Inc. Proprietary and Confidential. All rights reserved
UAV marketplace a moving target

UAVs are now in service in more than 50 countries. During 2007, these aircraft logged more than 500,000 flight hours, increase by logarithmic rate. Thousands of different aircraft in various stages of design, development or production. 70 active companies and nearly 200 unique platforms enter production or currently under development. Top 30 programs accounted for ~3,000 aircraft deliveries during 2008 and will deliver 3,350 more during 2009 about 93 percent of the delivery total. Over the next five years, the same programs will deliver about 13,000 aircraft. Over our 2009-2018 forecast period, they will account for close to 65 percent of expected UAV deliveries.
UAVs Future
Teal Group's 2010 market study estimates that UAV spending will more than double over the next decade from current worldwide UAV expenditures of $4.9 billion annually to $11.5 billion, totaling just over $80 billion in the next ten years. A new study reflects the rapid growth of interest in the UAV business by increasing the number of companies covered to almost 30 U.S., European and Israeli companies, and reflect the fundamental reshaping of the industrial environment
Types of UAVs
Target drones UAVs that simulate enemy missiles or aircraft in the demonstration and testing of antiaircraft and antiship missiles systems. Radar decoys Unmanned decoy aircraft deployed from a larger manned aircraft and designed to subvert, confuse or fool enemy radar systems. Information, surveillance and reconnaissance (ISR) aircraft UAVs that perform a variety of surveillance, observation and data-relay missions. For combat troops on the ground, small UAVs, including micro-UAVs (handheld/hand launched), provide over-the-hill scouting, to avoid ambushes and scare off insurgents. Unmanned combat aerial vehicles (UCAVs) Aircraft designed to provide unmanned weapons capabilities and support manned aircraft. Their capabilities include the use of bombs and missiles, electronic warfare equipment and directed-energy weapons.
Hyperworks A platform for Innovation

Modern FE Modeling
Ultimate post processing
Robust CFD solver
Explore, Study, Optimize
Motion Dynamic
Reduce weight
PA speed up projects
linear and non-linear simulations Altair Hyperworks is an engineering simulation environment which can use from engineers during all stages of the Design and Optimization of UAV's. From design stage when the engineer tests and validates new Shapes and mechanism and determine correct shapes for the engine inlet, determines optimum composite structure, reduce weight and provide more Payload.
Copyright InterFEA Engineering Inc. Proprietary and Confidential. All rights reserved 6
CFD Analysis & Optimization on UAV

From Design to the Reality of Flow Challenges Low Drag Cd High lift CL Less Noise Eliminate Turbulence
Coupling CFD + Optimization code Shapes for Optimization Post Processing Modeling for CFD
First 3D Design
Determination of pressure distribution on the surface of the UAV that later on leads to calculations of aerodynamics characteristics of uav such as CL, CD and CM at various angle of attack Visualization of the airflow around the UAV using Post Processing to recognize some critical area with possible vortex reduction in the near future. The analytical of aerodynamics characteristics for various angles of attacks using CFD simulation will be conducted in this final stage
Copyright InterFEA Engineering Inc. Proprietary and Confidential. All rights reserved 7
High Quality meshing for CFD

By using Hypermesh the total cost on human hours from Geometry cleanup to tetra mesh reduced by 60%. Special tools as Layer meshing & Refinement box option provides fast and accurate mesh for CFD analysis.
CFD Optimization of the Wing shape

The NACA 4412 Airfoil choose as an option for the UAVs wing, the NACA 4412 profile provides high CL on low speed for subsonic aircrafts. Several shapes (50) created for the optimization of the wing for reducing the CD and increase CL, in the same time several constrains have to be satisfied as volume and turbulence.
Optimized wing
The optimization of the wing create optimize performance as :
Cd
Cd reduction = 35% CL increased =5% Turbulence reduction = 21%
Optimized Cd /Iteration
Iterations
Initial
Optimized
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Optimized wing on several angles of attack

Lift Coefficient Analysis
For each wind tunnel airspeed, the value of CL increases as the angle of attack is increased until its maximum value at around = 35 and decreases afterwards with lower slope. Computational Fluid Dynamics (CFD) results at Mach 0.6 and 0.8 also give the same trend with maximum CL located at = 39 and = 35 respectively. It is observed that the value of CLmax increases as the air velocity of the wind tunnel is increased. Hence, the CL max increases with the increase of Reynolds number. This explains the difference of values of CL max between the experiments and the CFD.
Drag Coefficient Analysis

The variation of drag coefficient (CD) versus angle of attack () taken at different air speeds and Mach numbers. It is observed that the variation of drag coefficient is very slow and almost constant at low angle of attacks (below 8). In that range of , CD is small, below 0.03 for both experiments and CFD. As explained in the previous section, at low angle of attack, the air flow is still attached to the body and the wing. Above 8, CD grows at higher rate as is increased. Within this range, the wing is already in stall condition. Around 35, a slight deflection occurs on wind tunnel experiment curves. This is where the lift coefficient reaches its maximum value. This deflection is not clearly seen on the CFD curves. Beyond this angle of attack, the drag coefficient continues to increase with almost the same slope as between 8 and 34, and it is getting slower when approaches 90. From the overall curves, it is observed that higher airspeeds (or higher Reynolds number) produce higher drag coefficients.
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Nose Optimization
The optimization of the Nose create optimize performance as :
Morph volume & Shapes
Cd reduction = 18% CL increased =2% Turbulence reduction = 10%

Initial
Optimized
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Engine inlet Optimization

The optimization of the Engine Inlet create optimize performance as :
Cd reduction = 10% CL increased =2.89% Turbulence reduction = 12%

Initial
Morph volume & Shapes
Optimized
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Conclusions of the CFD & Structural Optimization

CFD Optimization Conclusions
Combat Radius Increased 34% Max take off load increased 10 %
CFD Analysis & Optimization

Cd Reduction : 51 % CL Increased : 9.89 %
Stabilization Problems Solved CL = Optimized Flight Load Cd = Fuel Consumption Reduction Optimized Inlet for Better Engine Performance Optimized Turbulence flow
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Structural Analysis and Optimization
Load transfer from Acusolve to Hypermesh for Linear Analysis and Optimization Data from: Angles of Attack 00, 50, 150, 200 Aerodynamic loads on the wing from extra external fuel tanks External Devices as cameras etc
Linear Interpolation
Pressure on the UAV surface
Structural model of the UAV
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Structural Analysis of the UAV wing
Analysis 25 Loadcases (strength, pressure) 370.000 Elements 15 Material types 842 Plies 145 Laminates
Aerodynamic Pressure on the wing surface
Composite Structure
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Structural Analysis of the UAV wing
The UAV Wing is made by CFRP Material, several parts are assembled to create the wing. The deformation of the wing and the stresses have been calculated by using Radioss (Bulk). The traditional design of the CFRP wing provide us a heavy structure
Deformation of the wing at angle of attack 00
Stresses on the wing at angle of attack 00
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Optimization of the CFRP wing using Optistruct

The optimization of the composite wing includes the optimization of each part composite - metal Loads : 25 loadcases (same as analysis) Model : 370 000 elements (same as analysis)
Skin Optimization
Objective : Reduce Weight

Safety Constrains : Strength, stability, strain Manufacturing Constrains : Thickness, Stacking etc
Metal Parts Optimizaiton
Optimal Structure
Ribs Optimization
Spars Optimization
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Steps of the wing skin optimization using Optistruct
Free-size optimization is used to identify the optimal ply shapes and locations of patches per ply orientation Size optimization is used to identify the optimal thicknesses of each ply bundle Shuffling optimization is used to obtain an optimal stacking sequence
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Free size optimization of the skin
Weight Reduction 32%
4 Plies with angles 0, 90, 45, -45 Thickness of each ply 4 mm Manufacturing Constrain : 00 & 900 min - 10% , max- 70%
Thickness of the Ply of 00

Thickness of the Ply of -450
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Size optimization
In the second design phase, a size optimization is performed to fine tune the thicknesses of the optimized ply bundles from Phase 1. To ensure that the optimization design meets the design requirements, additional performance criteria on natural frequencies and composite strains are incorporated into the problem formulation. Design variables: Ply thicknesses, which have been defined in the size input deck from Phase 1 Objective: Minimize the total designable volume Constraints: Natural frequencies (1st ~ 5th) > 0.06 KHz Composite strains in the wing < 1800 micro-strain Ply Thicknesses available 0,1 0,2- 0,3 0,4 mm
Plies of 00 in several point Plies of 900 in several point
Thickness 0.1 mm Thickness 0.25 mm Thickness 0.2 mm Thickness 0.3 mm
Thickness 0.1 mm Thickness 0.25 mm Thickness 0.2 mm Thickness 0.3 mm
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Shuffling optimization
Shuffling optimization is used to obtain an optimal stacking sequence
Design variables: Stacking seguence Objective: Optimize the stacking seguence Constraints: 1) The maximum successive number of plies of a particular orientation does not exceed 4 plies. 2) The + 45s and 45s are reversed paired
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Optimization using Optistruct

Optimization Conclusions Composite Parts Optimization
Total Weight Reduction 38 % Stiffness Increased 12% Stresses Decreased 30 % Deformation Decreased 15%
Optimized
Initial
39 % 32 % 25 % Main fuseland 22 % Wing structure Fuse skin Sub structures
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Optimization of other parts

Overall Structure Optimization
198 Parts Optimized with Optistruct 124 Composite parts 23 Connections simulated and optimized New material and technologies as Nanotubes in composites tested Manufacturing constrains increase manufacturing time more than 30% Thermal loads from the engine was simulated 24 Different maneuvers loads tested Total time for Development reduce by 40% Topology Optimization used for Ribs Topology Optimization used for Internal structure Turbulence loads during take off and landing that would cause issue eliminated at the stages of development
24
Optimization using Acusolve & Optistruct
Overall Conclusions
Payload 450 Kg
Payload 260 Kg
Combat Radius Increased by 45%
25
Thank you
InterFEA Engineering Innovative Engineering Solutions
Tantalou 7 Thessaloniki GREECE

info@interfea.com
26

Modeling, Structural &amp; CFD Analysis and Optimization of UAV

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Modeling, Structural & CFD Analysis and Optimization of UAV

Next Generation tools for UAVs

UAV marketplace a moving target

Hyperworks A platform for Innovation

Ultimate post processing

Robust CFD solver

Explore, Study, Optimize

CFD Analysis & Optimization on UAV

High Quality meshing for CFD

CFD Optimization of the Wing shape

Cd reduction = 35% CL increased =5% Turbulence reduction = 21%

Optimized wing on several angles of attack

Drag Coefficient Analysis

Cd reduction = 18% CL increased =2% Turbulence reduction = 10%

Engine inlet Optimization

Cd reduction = 10% CL increased =2.89% Turbulence reduction = 12%

Morph volume & Shapes

Conclusions of the CFD & Structural Optimization

CFD Analysis & Optimization

Structural Analysis and Optimization

Pressure on the UAV surface

Structural model of the UAV

Structural Analysis of the UAV wing

Aerodynamic Pressure on the wing surface

Structural Analysis of the UAV wing

Deformation of the wing at angle of attack 00

Stresses on the wing at angle of attack 00

Optimization of the CFRP wing using Optistruct

Objective : Reduce Weight

Optimization of the CFRP wing using Optistruct

Optimization of the CFRP wing using Optistruct

Weight Reduction 32%

Thickness of the Ply of 450

Thickness of the Ply of 900

Optimization of the CFRP wing using Optistruct

Thickness 0.1 mm Thickness 0.25 mm Thickness 0.2 mm Thickness 0.3 mm

Thickness 0.1 mm Thickness 0.25 mm Thickness 0.2 mm Thickness 0.3 mm

Optimization of the CFRP wing using Optistruct

Optimization using Optistruct

39 % 32 % 25 % Main fuseland 22 % Wing structure Fuse skin Sub structures

Optimization of other parts

Optimization using Acusolve & Optistruct

Combat Radius Increased by 45%

Tantalou 7 Thessaloniki GREECE

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