Detail wing design of Zen CH650 Aircraf

Literature survey
Zenith CH650 Data
parameter value
Crew 1
max passengers 1
propulsion Rotax 912s

engine power 74.57

Max speed 257
Range 1056
service ceiling 3692
max. Take-off weight 590
max landing weight 64500
empty weight 312
wing span 8.23
wing area 12.3
length 6.1
height 1.98
wing sweep angle 25
fuel capacity 92
landing distance 500
of Zen CH650 Aircraf
rvey
Data
unit

Kw
km/h
km airfoil
m
kg
kg
kg
m
m2
m
m
degree
l
f
g35-a-415 airfoil
 Design Load Calculations
Parameter Value Unit
Max. Take-off weight 590 kg
Max. Take-off weight 5787.9 N
Load factor 2.5
Lif 14469.75 N
Limit load 14469.75 N
Factor of safety 1.5
Ultimate load 21704.625 N
Design Load 21704.625 N
Pressure on the wing 1764.6036585366 N/m2

Geometrical Parameter calculations

Parameter Value Unit
Max speed 222.089 km/h
Max speed 61.6913888889 m/s
wing span (b) 8.23 m
wing area (s) 12.3 m2
wing sweep angle 25 degree
landing distance 500 f
Aspect ratio 5.5067398374
Taper ratio 0.3
Cr 2.2992803066 m
Ct 0.689784092 m
Cmac 1.6389741672
semi wing span 4.115 m
location of MAC (X) 1.6882051282 m
 Ref.
Assump.

Cr Ct

b/2
X
X=(b/6)*(Cr+2Ct)/(Cr+Ct)
 Aerodynamic considerations
Parameter Value Unit
Cruise speed (V) 61.6913888889 m/s
wing area (s ref) 12.3 m2
Max take off weight (W) 5787.9 N
Limit load 14469.75 N
Density 1.225 kg/m3
CL 0.504662143
Clmax 2.9435509457
Cf 0.0065
Swett/Sref 2.3
CDo 0.01495
e (span efficiency factor) 0.85
Aspect ratio 5.5067398374
CDi 0.0173283943
CD 0.0322783943
CL/CD 15.6346730831
S wet 28.29 m2

Airfoil selection
Parameter value
Cl 0.504662143
Cd 0.0322783943
AIRFOIL G35-A-415 airfoil

Chart Between Cl ,Cd and alfa

 Stall velocity calculation
Parameter Value Unit
Landing distance 500 feet
Approach velocity 40.8248290464 Knots
Stall velocity 31.4037146511 knots
1 Knots 0.514444 m/s
Stall velocity 16.15545258 m/s

CD=CDo+CDi

Cf=skin friction co-efficient

Reference airfoil points
x y z
 Spar Calculations
Parameter Value Unit
Front spar location 20 % of C
Rear spar location 70 % of C
Cr 2.2992803066 m
Front spar location 0.4598560613 m
Rear spar location 1.6094962146 m
CP location 45 % of C
CP location 1.034676138 m
Height of front spar 700.461 mm
height of rear spar 465.314 mm
Distance between spars 2766.433 mm
cg from front spar 1290.2142167334 mm
Front spar location 459.8560613141 mm
Cg location fron leading edge 1750.0702780475 mm
Cp location from front spar 1034.6761379568 mm
Cp-Cg -715.3941400907 mm
semi wing span 17.045 m
location of MAC (X) 6.9928205128 m

Shear force and bending moment Calculations

Parameter value unit
pressure on the wing 23104.7104404568 N/m2
Outer wing rib spacing (b) 0.7732445759 m
Inner wing rib spacing(c) 0.5379092702 m
Z 10.0521794872 m
Area Force
A26 2.853 F26
A25 2.789 F25
A24 2.726 F24
A23 2.662 F23
A22 2.598 F22
A21 2.534 F21
A20 2.471 F20
A19 2.407 F19
A18 2.343 F18
A17 2.279 F17
A16 2.216 F16
A15 2.152 F15
A14 2.088 F14
A13 3.143 F13
A12 2.747 F12
A11 2.615 F11
A10 2.266 F10
 A9 2.363 F9
A8 2.232 F8
A7 2.1 F7
A6 1.962 F6
A5 1.837 F5
A4 1.705 F4
A3 1.573 F3
A2 1.442 F2
A1 1.31 F1

Y1 350.23 mm
Y2 297.115 mm

Front Spar calculation

Parameter Value Unit
Total moments 9255335.58605083 N-m
Total moments 9255335586.05083 N-mm
Front spar moment (M) 4938814797.81523 N-mm
Y 350.23 mm
Sigma 538 Mpa
I 3215094993.75247 mm4
height of front spar 700.461 mm

N-mm mm4 mm
M I Y
4938814797.81523 4733812394 350.23

Rear Spar calculation

Parameter Value Unit
Total moments 1187436.57405299 N-m
Total moments 1187436574.05299 N-mm
Front spar moment (M) 553798898.911458 N-mm
Y 297.115 mm
Sigma 538 Mpa
I 305840074.070777 mm4
height of rear spar 465.314 mm

N-mm mm4 mm
M I Y
553798898.911458 449797200.520833 297.115
Force Shear force
65917.7388866233 SFroot 1300102.0564845
64439.037418434 SF25 1306802.42251224
62983.4406606852 SF24 1186750.34706362
61504.739192496 SF23 1179379.94443312
60026.0377243068 SF22 1062262.16721044
58547.3362561175 SF21 1057849.16751631
57091.7394983688 SF20 947732.117557098
55613.0380301795 SF19 942210.091761829
54134.3365619903 SF18 813978.948817293
52655.6350938011 SF17 832462.717169659
51200.0383360523 SF16 779807.082075858
49721.336867863 SF15 728607.043739805
48242.6353996738 SF14 639492.175570963
72618.1049143557 SF13 630643.071472268
63468.6395799348 SF12 558024.966557913
60418.8178017945 SF11 494556.326977978
52355.2738580751 SF10 382567.795473084
54596.4307707994 SF9 381782.235318108
51569.7137030996 SF8 327185.804547309
48519.8919249593 SF7 275616.090844209
45331.4418841763 SF6 227096.19891925
42443.3530791191 SF5 181764.757035074
39393.5313009788 SF4 139321.403955955
36343.7095228385 SF3 99927.8726549757
33316.9924551387 SF2 63584.1631321371
30267.1706769984 SF1 30267.1706769984
SFtip 0

Mpa RF
sigma 1.4723709263
365.3970547779

b1 b2
750 220
mm mm
A1 A2
45000 127701.42
mm2 mm2
Hy1 Hy2
320.2305 0
mm mm
Ixx Iyy
12841871118.2719 4733812394
Mpa mm4 mm4
sigma
365.8136592659 RF
1.4706941263

b1 b2
425 125
mm mm
A1 A2
12750 50664.25
mm2 mm2
Hy1 Hy2
217.657 0
mm mm
Ixx Iyy
1903555238.29012 449797200.520833
mm4 mm4
 rear spar 0.4663818776 46.6381877578 %
front spar 0.5336181224 53.3618122422 %

bending moment
BMroot 9255335.58605
BM25 8587361.29606
BM24 7928496.90447
BM23 7303903.37898
BM22 6712791.52648
BM21 6154365.93974
BM20 5627831.21153
BM19 5132398.14874
BM18 4667277.55827
BM17 4231674.03289
BM16 3864910.51741
BM15 3459215.5466
BM14 3080663.84745
BM13 2728460.0127 1400000
BM12 2268894.4562
1200000
BM11 1861943.06822
BM10 1502889.33247 1000000

800000

600000
 1400000

1200000

1000000
BM9 1187436.57405
BM8 913333.728384 800000
BM7 680277.080396
600000
BM6 603008.39488
BM5 327842.546486 400000
BM4 203703.480288
200000
BM3 111204.37757
BM2 47986.9801837 0
BM1 11701.9627775
BMtip 0

b3

d3

d2

b2

d1

b1
b3 d1 d2 d3
750 60 580.461 60
mm mm mm mm
A3 x1 x2 x3 y1
45000 375 375 375 30
mm2 mm mm mm mm
Hy3 Hx1 Hx2 Hx3
-320.2305 0 0 0
mm mm mm mm
Moment
 b3

d3

d2

b2

d1

b1
b3 d1 d2 d3
425 30 405.314 30
mm mm mm mm
A3 x1 x2 x3 y1
12750 212.5 212.5 212.5 15
mm2 mm mm mm mm
Hy3 Hx1 Hx2 Hx3
-217.657 0 0 0
mm mm mm mm
Moment
 10000000
9000000
8000000
7000000
6000000
5000000

Column F 4000000 Column H

 10000000
9000000
8000000
7000000
6000000
5000000

Column F 4000000 Column H

3000000
2000000
1000000
0

Y
h

y2 y3 X_ Y_
350.2305 670.461 375 350.2305
mm mm mm mm

Moment of inertia
 Y
h

y2 y3 X_ Y_
232.657 450.314 212.5 232.657
mm mm mm mm

Moment of inertia
Column H
Column H
 Ribs Calculations
Parameter Value Unit
Semi wing span 4.115 m
Root to MAC location 6.9928205128 m
MAC to Tip -2.8778205128 m
Total No. of Ribs 25
Outer wing rib spacing -0.2213708087 m
Inner wing rib spacing 0.5379092702 m
 MATERIAL SEL
Aluminium alloy se
Alloy series Alloying element
1xxx Pure Aluminium(99%)
2xxx Copper
3xxx Manganese
4xxx Silicon
5xxx Magnesium
6xxx Magnesium+Silicon
7xxx Zinc
8xxx Lead

2xxx Tension dominent

7xxx Compression dominent

Part Material selected Reas

Lower part of wing Al 2024-T3 As the lower part of the wing undergoes tensi
Upper part of the wing Al 7075-T6 As the upperer part of the wing undergoes compress
Leading edge Al-clad For de-iceing,bulk
 MATERIAL SELECTION
Aluminium alloy series
Alloy category Ultimate tensile strength Properties
Commercially pure
Heat-Treatable 449 Mpa Strong,age-hardening(tension-dominant)
Non Heat-Treatable
Non Heat-Treatable
Non Heat-Treatable
Heat-Treatable
Heat-Treatable 538 Mpa Strong,age-hardening(Compression-dominant)
Heat-Treatable

Reason
As the lower part of the wing undergoes tension and al 2024 is the best tension dominant
he upperer part of the wing undergoes compression and al 7075 is the best compression dominant
For de-iceing,bulk stag resistance
 Typical Uses

Aircraft skin,spars,forging,rivets

Aircraft forging,spars,railway carriage

 Thickness
Skin thickness 1.2 mm
Rib thickness 2 mm
Spar web thickness(front) mm
Spar web thickness(rear) mm
At root chord
Spar flange thickness(front) mm Spar
Spar flange thickness(rear) mm cross-
Spar web thickness(front) mm section
(I-section)
Spar web thickness(rear) mm
At tip chord
Spar flange thickness(front) mm
Spar flange thickness(rear) mm

Weight estimation
Front spar 4431.946 kg
Rear spar 1637.394 kg
Skin 690.223 kg
Ribs 195.849 kg
Total weight 6955.412 kg
 Spar Cross-sections
Front spar cross-section (Root to Tip)
Locations flenge width flenge thickness web thickness
Root 750 60 200
Rib25 736.017 58.741 195.582
rib24 719.391 57.413 191.164
Rib23 702.764 56.085 186.746
Rib22 686.138 54.757 182.327
Rib21 669.511 53.43 177.909
Rib20 652.885 52.102 173.491
Rib19 636.259 50.775 169.073
Rib18 619.632 49.447 164.655
Rib17 603.006 48.12 160.237
Rib16 586.379 46.793 155.819
Rib15 569.753 45.466 151.4
Rib14 553.126 44.139 146.982
Rib13 536.5 42.812 142.564
Rib12 510.453 40.733 135.643
Rib11 486.552 38.825 129.292
Rib10 462.652 36.918 122.941
Rib9 440.898 35.182 117.16
Rib8 416.997 33.275 110.809
Rib7 393.097 31.368 104.458
Rib6 369.196 29.46 98.107
Rib5 345.296 27.554 91.755
Rib4 321.395 25.647 85.404
Rib3 297.495 23.74 79.053
Rib2 273.594 21.833 72.702
Rib1 249.694 19.927 66.351
Tip 225 18 60
-sections
Rear spar cross-section (Root to Tip)
Locations flenge width flenge thickness web thickness
Root 425 30 125
Rib25 428.377 29.586 122.239
rib24 408.926 28.917 119.477
Rib23 399.475 28.248 116.716
Rib22 390.024 27.579 113.955
Rib21 380.573 26.91 111.193
Rib20 371.122 26.241 108.432
Rib19 361.671 25.572 105.671
Rib18 352.22 24.903 102.909
Rib17 342.769 24.234 100.148
Rib16 333.318 23.566 97.387
Rib15 323.867 22.897 94.625
Rib14 314.416 22.229 91.864
Rib13 304.965 21.56 89.103
Rib12 290.159 20.513 84.777
Rib11 276.573 19.552 80.807
Rib10 262.987 18.592 76.838
Rib9 250.621 17.718 73.225
Rib8 237.036 16.757 69.255
Rib7 223.45 15.797 65.286
Rib6 209.864 14.836 61.317
Rib5 196.278 13.876 57.347
Rib4 182.692 12.916 53.378
Rib3 169.105 11.956 49.408
Rib2 155.52 10.996 45.439
Rib1 141.964 10.036 41.469
Tip 127.5 9 37.5