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Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design
For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.
The design of an airfoil for a high-altitude, long-endurance remotely piloted vehicle
Airfoil design efforts are studied. The importance of integrating airfoil and aircraft designs was demonstrated. Realistic airfoil data was provided to aid future high altitude, long endurance aircraft preliminary design. Test cases were developed for further validation of the Eppler program. Boundary layer, not pressure distribution or shape, was designed. Substantial improvement was achieved in vehicle performance through mission specific airfoil designed utilizing the multipoint capability of the Eppler program.
Efficient Viscous Design of Realistic Aircraft Configurations
This paper addresses the use of the Constrained Direct Iterative Surface Curvature (CDISC) design method in the aircraft design process. A discussion of some of the requirements for practical use of CFD in the design process is followed by a description of different CFD design methods, along with their relative strengths and weaknesses. A detailed description of the CDISC design method highlights some of the aspects of the method that provide computational efficiency and portability, as well as the flow and geometry constraint capabilities. In addition, an efficient approach to multipoint design, the Weighted Averaging of Geometries (WAG) method, is described and illustrated using a couple of simple examples. The CDISC and WAG methods are then applied to a complex generic business jet geometry using an unstructured grid flow solver to demonstrate the multipoint and multicomponent design capabilities of these methods. Introduction
Advanced Usage of Vehicle Sketch Pad for CFD-Based Conceptual Design
Conceptual design is the most fluid phase of aircraft design. It is important to be able to perform large scale design space exploration of candidate concepts that can achieve the design intent to avoid more costly configuration changes in later stages of design. This also means that conceptual design is highly dependent on the disciplinary analysis tools to capture the underlying physics accurately. The required level of analysis fidelity can vary greatly depending on the application. Vehicle Sketch Pad (VSP) allows the designer to easily construct aircraft concepts and make changes as the design matures. More recent development efforts have enabled VSP to bridge the gap to high-fidelity analysis disciplines such as computational fluid dynamics and structural modeling for finite element analysis. This paper focuses on the current state-of-the-art geometry modeling for the automated process of analysis and design of low-boom supersonic concepts using VSP and several capability-enhancing design tools.
Proceedings of the 8th Annual Summer Conference: NASA/USRA Advanced Design Program
Papers presented at the 8th Annual Summer Conference are categorized as Space Projects and Aeronautics projects. Topics covered include: Systematic Propulsion Optimization Tools (SPOT), Assured Crew Return Vehicle Post Landing Configuration Design and Test, Autonomous Support for Microorganism Research in Space, Bioregenerative System Components for Microgravity, The Extended Mission Rover (EMR), Planetary Surface Exploration MESUR/Autonomous Lunar Rover, Automation of Closed Environments in Space for Human Comfort and Safety, Walking Robot Design, Extraterrestrial Surface Propulsion Systems, The Design of Four Hypersonic Reconnaissance Aircraft, Design of a Refueling Tanker Delivering Liquid Hydrogen, The Design of a Long-Range Megatransport Aircraft, and Solar Powered Multipurpose Remotely Powered Aircraft.
FLUTTER CALCULATION WITH MANY DEGREES OF FREEDOM FOR MODERN
Flutter calculations with many degrees of freedom for modern aircraft designs
Probing the Sky: Selected NACA Research Airplanes and Their Contributions to Flight
This NASA SP will discuss the discovery of airflow compressibility and the early X-planes used to explore the phenomena, as well as other discoveries that paved the way for modern aircraft design.
V/STOL aircraft and fluid dynamics
The impact of military applications on rotorcraft and V/STOL aircraft design is summarized with respect to fixed-wing aircraft. The influence of the mission needs on the configurational design of V/STOL aircraft, the implications regarding some problems in fluid dynamics relating to propulsive flows, and their interaction with the aircraft and the ground plane, are also considered. Additional research in fluid dynamics that can contribute to an improvement in performance of V/STOL aircraft is suggested.
Bringing v/stols downtown.
V/STOL aircraft design for short haul intercity travel in terms of operating costs, all-weather instruments and noise control
Motion-Based Piloted Simulation Evaluation of a Control Allocation Technique to Recover from Pilot Induced Oscillations
This paper describes the maturation of a control allocation technique designed to assist pilots in the recovery from pilot induced oscillations (PIOs). The Control Allocation technique to recover from Pilot Induced Oscillations (CAPIO) is designed to enable next generation high efficiency aircraft designs. Energy efficient next generation aircraft require feedback control strategies that will enable lowering the actuator rate limit requirements for optimal airframe design. One of the common issues flying with actuator rate limits is PIOs caused by the phase lag between the pilot inputs and control surface response. CAPIO utilizes real-time optimization for control allocation to eliminate phase lag in the system caused by control surface rate limiting. System impacts of the control allocator were assessed through a piloted simulation evaluation of a non-linear aircraft simulation in the NASA Ames Vertical Motion Simulator. Results indicate that CAPIO helps reduce oscillatory behavior, including the severity and duration of PIOs, introduced by control surface rate limiting.
Final design proposal: Theta Group-The Hotbox. A proposal in response to a commercial air transportation study
The Hotbox is a 40 passenger commercial aircraft designed to have a minimum range of 5500 ft and cruise at a velocity of 30 ft/sec. The aircraft is designed to serve the longer range overseas market in Aeroworld. In order to serve all the airports in the overseas market, the Hotbox was required to be able to use a five foot gate. A weight requirement was set a 4.5 lbs in order to maximize aircraft efficiency. Finally, a single engine system was chosen because it minimized system weight, complexity and cost. The Hotbox is estimated to cost $152,000 Aeroworld dollars and will sell for $200.000. The propulsion system for the Hotbox consists of a nose mounted Astro 15 electric powered motor and a Top Flight 12-6 propeller. A Spica airfoil was selected for the Hotbox based on the ease of construction of its flat bottom and its positive lift and drag characteristics. A fuselage of rectangular cross section will internally contain the propulsion system, control system, and a passenger bay with 2x20 seating. A combination of directional and longitudinal control will enable the Hotbox to maneuver. The final design of the Hotbox provides for takeoff distance in 26.5 ft and normal cruise range of 17,000 ft.
Drag Prediction for the DLR-F4 Wing/Body using OVERFLOW and CFL3D on an Overset Mesh
This paper reviews the importance of numerical drag prediction in an aircraft design environment. A chronicle of collaborations between the authors and colleagues is discussed. This retrospective provides a road-map which illustrates some of the actions taken in the past seven years in pursuit of accurate drag prediction. The advances made possible through these collaborations have changed the manner in which business is conducted during the design of all-new aircraft. The subject of this study is the DLR-F4 wing/body transonic model. Specifically, the work conducted herein was in support of the 1st CFD Drag Prediction Workshop, which was held in conjunction with the 19th Applied Aerodynamics Conference in Anaheim, CA during June, 2001. Comprehensive sets of OVERFLOW simulations were independently performed by several users on a variety of computational platforms. CFL3D was used on a limited basis for additional comparison on the same overset mesh. Drag polars based on this database were constructed with a CFD-to-Test correction applied and compared with test data from three facilities. These comparisons show that the predicted drag polars fall inside the scatter band of the test data, at least for pre-buffet conditions. This places the corrected drag levels within 1% of the averaged experimental values. At the design point, the OVERFLOW and CFL3D drag predictions are within 1-2% of each other. In addition, drag-rise characteristics and a boundary of drag-divergence Mach number are presented.
Simulator Study of Indoor Annoyance Caused by Shaped Sonic Boom Stimuli With and Without Rattle Augmentation
The National Aeronautics and Space Administration's High Speed Project is developing a predictive capability for annoyance caused by shaped sonic booms transmitted indoors. The predictive capability is intended for use by aircraft designers as well as by aircraft noise regulators who are considering lifting the current prohibition on overland civil supersonic flight. The goal of the current study is to use an indoor simulator to validate two models developed using headphone tests for annoyance caused by sonic booms with and without rattle augmentation. The predictors in the proposed models include Moore and Glasberg's Stationary Loudness Level, the time derivative of Moore and Glasberg's time-varying short-term Loudness Level, and the difference between two weighted sound exposure levels, CSEL-ASEL. The indoor simulator provides a more realistic listening environment than headphones due to lowfrequency sound reproduction down to 6 Hz, which also causes perceptible tactile vibration. The results of this study show that a model consisting of {PL + (CSEL-ASEL)} is a reliable predictor of annoyance caused by shaped sonic booms alone, rattle sounds alone, and shaped sonic booms and rattle sounds together.
Semi-reactive stratoplane /1932/
High altitude, high speed aircraft design parameters - thrust, combustion, and dynamics
Aircraft digital control design methods
Variations in design methods for aircraft digital flight control are evaluated and compared. The methods fall into two categories; those where the design is done in the continuous domain (or s plane) and those where the design is done in the discrete domain (or z plane). Design method fidelity is evaluated by examining closed loop root movement and the frequency response of the discretely controlled continuous aircraft. It was found that all methods provided acceptable performance for sample rates greater than 10 cps except the uncompensated s plane design method which was acceptable above 20 cps. A design procedure based on optimal control methods was proposed that provided the best fidelity at very slow sample rates and required no design iterations for changing sample rates.
Integration of Off-Track Sonic Boom Analysis in Conceptual Design of Supersonic Aircraft
A highly desired capability for the conceptual design of aircraft is the ability to rapidly and accurately evaluate new concepts to avoid adverse trade decisions that may hinder the development process in the later stages of design. Evaluating the robustness of new low-boom concepts is important for the conceptual design of supersonic aircraft. Here, robustness means that the aircraft configuration has a low-boom ground signature at both under- and off-track locations. An integrated process for off-track boom analysis is developed to facilitate the design of robust low-boom supersonic aircraft. The integrated off-track analysis can also be used to study the sonic boom impact and to plan future flight trajectories where flight conditions and ground elevation might have a significant effect on ground signatures. The key enabler for off-track sonic boom analysis is accurate computational fluid dynamics (CFD) solutions for off-body pressure distributions. To ensure the numerical accuracy of the off-body pressure distributions, a mesh study is performed with Cart3D to determine the mesh requirements for off- body CFD analysis and comparisons are made between the Cart3D and USM3D results. The variations in ground signatures that result from changes in the initial location of the near-field waveform are also examined. Finally, a complete under- and off-track sonic boom analysis is presented for two distinct supersonic concepts to demonstrate the capability of the integrated analysis process.
The promise of energy-efficient battery-powered urban aircraft
Improvements in rechargeable batteries are enabling several electric urban air mobility (UAM) aircraft designs with up to 300 mi of range with payload equivalents of up to seven passengers. Novel UAM aircraft consume between 130 Wh/passenger-mi and ∼ 1,200 Wh/passenger-mi depending on the design and utilization, compared to an expected consumption of over 220 Wh/passenger-mi and 1,000 Wh/passenger-mi for terrestrial electric vehicles and combustion engine vehicles, respectively. We also find that several UAM aircraft designs are approaching technological viability with current Li-ion batteries, based on the specific power and energy, while rechargeability and lifetime performance remain uncertain. These aspects highlight the technological readiness of a new segment of transportation.