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W. Grodzki1, A. Łukaszewicz1
tools designers meaningfully decrease price of the ished structure. Components of composites due to
introduction of new product [1, 2]. their function can be divided into filler (reinforce-
Due to high requirements of the modern UAV’s ment) and matrix. Mostly used matrices materials
(high strength-low weight) composite materials are polymers, metals, ceramics and carbon while fil-
especially polymer matrix composites reinforced lers materials are glass, carbon, aramid and boron.
with continues fibers are most appropriate choice Reinforcement occur in different forms: continues
[3]. These materials are characterized by Young fibers, short fibers and particles [4].
module twice as high compared to aluminum alloys
while retaining two times lower weight. Difficulties 2.1 Polymer matrix composites
in use of composites materials are related to the ani-
Polymer matrix composites are most common due to
sotropic/orthotropic structure. Use of these materials
low costs of fabrication and attractive properties:
in numerical analysis requires knowledge of material
low density, high strength, high stiffness, corrosion
constants and mechanical properties in principal
resistance and vibration damping ability. Reinforced
axes. Only fully defined composite material guaran-
with continues fibers obtain mechanical properties
tees real structure behavior and reliability of calcula-
similar or higher than conventional materials and
tion results [4].
present high strength-to-weight and stiffness-to-
Development of wings for unmanned aerial vehi-
weight ratio. Therefore polymer matrix composites
cle is a multistage task which includes: airfoil selec-
reinforced with continues fibers are widely used for
tion, geometrical calculations, structural design, ma-
lightweight structures, for example in aviation as
terials selection, numerical analysis and manufactur-
parts of airframes structures. The most common ma-
ing. Main task of wing development process is to de-
terials used for matrices are vinyl ester, epoxy, phe-
sign structure characterized by high strength along
nol, formaldehyde (PF), polyamide (PI) polyimide
with low weight.
and polypropylene (PP) resins. Fillers due to the
form of occurrence may take the form of mats (made
2 Composite materials form short fibers) or fabrics (continue fibers) [5].
The most frequent occurring types of fabrics used as
Composite materials consist of two or more phases reinforcement for polymer composites are: plain
with significantly different properties (physical, weave, twill wave, satin weave and unidirectional
chemical). Combined together they form a material fabric. Table 1 shows the mechanical properties of
with characteristics different from individual compo- selected polymer (epoxy resin) matrix composites
nents. Each phase remain separate within the fin- [6].
construction. SolidWorks environment gave possibi- SolidWorks Simulation gave possibility to ana-
lity to control weight of created structure at early de- lyze composites up to 50 individual layers [15].
sign stage, Figure 4. Software assumes perfect bond between them. Most
common types of composites available in Solid-
3.4 Numerical analysis Works Simulation are:
Strength analysis is closely related to the structural • Symmetric laminate – defined by symmetrical
design (in our case UAV wing) verifying given geo- distributed layer thicknesses, fiber orientations
metry and used materials under posed boundary con- and properties of the layers.
ditions. In order to improve the accuracy of numeri- • Asymmetric laminate – characterized by no sym-
cal analysis solid model has been replaced by a sur- metry of used layers, orientations and properties
face model preserving geometrical dimensions. in reference to central plane.
Defining materials in SolidWorks environment re- • Sandwich materials – special case of symmetric
quires describing properties such as Elastic modulus laminates with central layer characterized by
E, Poisson ratio ν, shear modulus G, tensile strength, greater thickness and lower mechanical properties
compressive strength, density. For complete charac- compared to other layers. Used when higher
terization of orthotropic materials (composites used resistance to bending load is required.
in analysis) six materials constants are required
(properties in two axes are the same) and following Composite property manager allows to set required
mechanical properties: tensile strength and compres- number of layers, thicknesses, orientations and layer
sive strength in two directions, shear strength in xy, materials. This tool shows laminate coordinate sys-
density [12]. Thermal properties have been omitted tem and direction of each individual layers. It is im-
due to nature of the analysis. In course of analysis portant to point that coordinate system of composite
Rohacel IG 71 and Balsa wood were considered as is not the same as model or assembly. In considered
isotropic structures. Mechanical properties of materi- case numbers of layers was set to 4/5 depending on
als used in analysis are presented in Table 2 [13, type of analyzed structure. Thickness of composites
14]. layers amounted 0.3 mm and foam core 3 mm. Or-
ientations of layers were as follows [45/90/90/45], analysis it was necessary to create finite element
[45/90/0/90/45], Figure 5. mesh. Applied mesh density was equally distributed
Boundary conditions based on wing static test for the whole model (global size of element 2.4 mm,
used in analysis involved attaching wings at the tolerance 0.12). Figure 6 presents discussed bound-
ends, applying external load in middle of the struc- ary conditions with external load of 300 N (wing
ture. In flight conditions such test simulate overload span 1000 mm, length of composite structure
of 2.5 g. Fixation of tested element was carried out 88.5 mm, height of structure 32 mm)
by taking off translations at the ends of the wing in For the analysis, the iterative solver FFE Plus
X and Y axis while translation in the Z-axis was tak- were applied. This method uses approximate techni-
en away on rib in the middle of the structure (such ques to calculate the solution and repeat the process
fixing allows displacement of wing tips in Z-axis re- until the difference between two consecutive solu-
flecting exact terms of static test). For purpose of tions is significantly small or does not exceed set er-
Figure 7. Displacement of carbon-glass fiber lamina (left side), sandwich structure (right side)
Bild 7. Die Verschiebung der Sandwichstruktur (rechts), Kohlenstoff-Glasfaser-Schichten (links)
Figure 8. Stress Intensity (P1-P3) of carbon-glass fiber lamina (left side), sandwich structure (right side)
Bild 8. Spannungsintensität (P1-P3) der Sandwichstruktur (rechts), Kohlenstoff-Glasfaser-Schichten (links)
ror limits [16]. Studies have also been carried out structure occurring stress is two and half times lower
using the Direct Sparse solver (appropriate when than in laminate composite. Assuming that both
solving assemblies of parts with widely different ma- structures satisfy project assumptions, sandwich
terial properties). Calculation results of both solvers structure due to lower stress intensity, could be man-
overlapped (FEE plus perform calculations faster). ufactured with thinner layer of carbon fiber thus re-
During the analysis two cases of composite struc- ducing weight of the designed element.
ture were considered: For complete description of design structure it is
necessary to perform analysis allowing to present
• sandwich construction based on carbon/glass fab-
types of loads with their occurrence. SolidWorks en-
ric/epoxy resin laminate filled with balsa ribs
vironment gives possibility to analyze state and the
• sandwich construction based on carbon/glass fab-
type of stress on each individual layer of tested
ric/foam core/epoxy resin sandwich composite
composite. Figure below shows values and distribu-
filled with balsa wood ribs for proper shape.
tion of tensile (P1-1st Principal Stress) and compres-
Evaluation of the test results will begin with displa- sive stresses (P3-Third Principal Stress) appearing
cement plots analysis, Figure 7. It represents the re- on carbon fiber layers of examined structure, Fig-
sultant displacement (it is possible to check displace- ure 9.
ment in requested axis) of the object under the influ- As predicted tensile stress appeared mostly on the
ence of applied forces and restraints. Notable is three lower part of construction while compressive stress
times smaller deflection in the structure consisting of occurred on the upper part. Difference of stresses val-
foam core. Difference in weight between two ana- ues varies between two and four times lower in case
lyzed composites is negligible. Stiffness of the struc- of sandwich composite. Such large divergences are
ture is very important aspect in the design of air- the result of different tendencies in the occurrence of
frame because change in geometry resulting from stress fields in considered structures. SolidWorks Si-
deflection affects significantly aerodynamics of cre- mulation allows to analyze not only differences of
ated aircraft. stresses on layers but also on sides (top, bottom) of
Next analyzed plot presents distribution of highest individual layer. On the basis of analysis noticeable
values of “stress intensity”, which is defined as is existence of tensile and compressive stresses on
P1-P3 = 2 ∙ τmax, occurring in researched structure both sides of researched composites. It is caused by
(P1-1st and P3-3rd principal stresses), Figure 8. geometry of examined structure (open composite
“Stress intensity” value is based on Tresca yield cri- profile filled with balsa ribs) and type of applied
terion and in complex stress state is more conserva- load. Analyzing the points of occurrence of the lar-
tive then HMH criterion. Stresses intensities shown gest tensile and compressive stress on the lower and
at figure below are expressed in absolute value upper surface with respect to the layers of the com-
which means types of load (tension, compression) posite and side of the layer, provides information
are not taken into account only their equivalent max- about the tendencies of stress occurrence across con-
imum value. It can be noted that in case of sandwich sidered element.
Figure 9. Tensile (P1) and compressive stress (P3) of carbon-glass fiber lamina (left side), sand-
wich structure (right side)
Bild 9. Zug (P1) und Druckspannung (P3) der Sandwichstruktur (rechts), Kohlenstoff-Glasfaser-
Schichten (links)
Above analysis allows to determine structure be- compatibility of design structure geometry and man-
havior and stress appearance in respect to given geo- ufactured one is crucial. Small change arising from
metry and used materials. Gathered information en- inaccuracies of execution have significant impact on
ables designer to create structure satisfying the re- the aerodynamic properties of considered airframe.
quirements set out in the project, Table 3. Materials used for wing construction (based on
above design) are mostly fibrous polymer compo-
sites (glass fiber, carbon fiber) with foam (based on
4 Manufacture polymath-acrylimide) and balsa wood.
Sandwich structure used in abovementioned air-
Development of manufacturing technology is an im- frame is main bearing element, therefore manufac-
portant step in creation process of new construction turing this part without defect is very important is-
due to affect on final product quality. In aviation sue. Vacuum bag technique excludes occurrence of
void (bubbles and wrinkles) in created composite Described manufacture and design methodology
which is main advantage of this method. Vacuum of UAV wing structure was used to build aircraft for
bagging use atmospheric pressure to hold laminate Air Cargo Challenge 2013 competitions, Figure 13.
layers together. By this method it is possible to man- Among twenty one teams that arrived from all over
ufacture composites with high fiber content which the world our “Podlasie Tigers” team took 10th
translate into higher strength to weight ratios [17]. In place [19]. Largest payload of our classified flight
order to create structure based on given geometry amounted 5 kg (airplane weight was 2.2 kg). Heavi-
necessary is, to make mold with exact shape, Fig- est payload we have managed to pick up during
ure 10. whole competition was 7 kg (over three times the
CAD model of wing was used to obtain mold plane weight) however conditions (strong gusts of
model [18]. Next, using CAM software, G-code was wind) did not allow to continue the flight.
generated for CNC milling machine. Bottom and top
parts of mold was made from MDF panel. Having
machined molds, it was necessary to prepare sur- 5 Conclusions
faces by painting and polishing them. (obtained
smoothness has a large impact on composite qual- Development of wing for unmanned aerial vehicle is
ity). Owning prepared molds it is possible to per- a multistage task which includes: airfoil selection,
form lamination using vacuum bag technique, Fig- geometrical calculations, structural design, materials
ure 11. selection, numerical analysis and elaboration of tech-
Having manufactured composite structure final nology. Polymer matrix composites widely used in
step of creating wing construction was attaching bal- aviation industry characterize by high strength-to-
sa wood ribs in order to obtain desired shape and weight and stiffness-to-weight ratio. Due to high re-
geometry. It is useful to reinforce balsa elements quirements of the modern UAV’s (high strength-low
with carbon fiber and apply carbon bar for better weight) composite materials are only appropriate
stiffness, Figure 12. choice.