UMaine SAE Aero Design Final Report

87 Pages·2015·4.75 MB·English

Design, Construction and Testing Of A Remote Operation
Heavy-Lift Model Aircraft

Capstone Final Report

Mechanical Engineering
Class of 2013

Original: 07 MAY 2013

Reformatted:
FEB 2015

University of Maine
SAE Aero Design:

Benjamin Waller, MEE

David Chandpen, MEE

Joseph Travaglini, MEE

Matthew Maberry, MEE

Travis Cushman, MEE

Zachary Veilleux, MEE

Abstract

The UMaine SAE Aero Capstone group is designed around an annual competition held by the Society of
Automotive Engineers. The main goal of the competition is to design and construct an aircraft that can lift
more payload than other teams while staying within the rules and restrictions of the SAE Aero Competition
guidelines. This capstone group represents the first iteration of this challenge attempted by the University
of Maine. This team did not attend the competition but rather the aim was to design and build an aircraft
that was competition worthy. The following report is a summary of the design process, decisions, analysis,
substantiation, and final results of the project.
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1. Table of Contents

1. Table of Contents ............................................................................................................................... - 3 -
2. Table of Figures ................................................................................................................................. - 6 -
3. Contributions ..................................................................................................................................... - 8 -
4. Introduction ....................................................................................................................................... - 9 -
1.1 Project Beginnings .................................................................................................................... - 9 -
1.2 SAE Aero Design Competition ................................................................................................. - 9 -
1.3 MEE Capstone Project and Associated Opportunities .............................................................. - 9 -
1.4 Aerospace Studies at the University of Maine ........................................................................ - 10 -
1.5 Summary of Focus and Objectives ......................................................................................... - 10 -
5. Design Description .......................................................................................................................... - 11 -
2.1 Components and Systems ....................................................................................................... - 11 -
2.2 Engine ..................................................................................................................................... - 11 -
2.3 Wing........................................................................................................................................ - 11 -
2.4 Fuselage .................................................................................................................................. - 12 -
2.5 Wireless Systems .................................................................................................................... - 12 -
2.6 Controls ................................................................................................................................... - 13 -
2.7 Empennage .............................................................................................................................. - 13 -
2.8 Landing Gear / Externals ........................................................................................................ - 13 -
6. Design Concept Process................................................................................................................... - 14 -
3.1 Engine Selection ..................................................................................................................... - 14 -
3.2 Airfoil Selection ...................................................................................................................... - 14 -
3.2.1 Design Goal .................................................................................................................... - 14 -
3.2.2 Research Done ............................................................................................................... - 14 -
3.2.3 Operating Conditions ..................................................................................................... - 14 -
3.2.4 Resources Utilized.......................................................................................................... - 15 -
3.3 Testing .................................................................................................................................... - 15 -
3.4 Results Discussion .................................................................................................................. - 16 -
7. Wing Configuration ......................................................................................................................... - 17 -
4.1 Wing Design ........................................................................................................................... - 17 -
4.2 Wing Section ........................................................................................................................... - 17 -
4.3 Design Goal ............................................................................................................................ - 18 -
4.4 Research Done ........................................................................................................................ - 18 -
4.4.1 Wing Span ...................................................................................................................... - 18 -
4.4.2 Wing Span with Reynolds Number ................................................................................ - 18 -
4.4.3 Chord Length ................................................................................................................. - 20 -
4.4.4 Aspect Ratio ................................................................................................................... - 21 -
4.4.5 Wing Mounting Style ..................................................................................................... - 21 -
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4.4.6 Dihedral Angle ............................................................................................................... - 22 -
4.4.7 Taper .............................................................................................................................. - 23 -
4.4.8 Twist ............................................................................................................................... - 23 -
4.4.9 Wing Sweep ................................................................................................................... - 23 -
4.4.10 Edge Design ................................................................................................................... - 23 -
4.4.11 Wing Loading ................................................................................................................. - 24 -
4.4.12 Externals ......................................................................................................................... - 24 -
4.4.13 Multiple Wings ............................................................................................................... - 24 -
4.4.14 Final Wing Size and Configuration ................................................................................ - 25 -
4.4.15 Construction and Components ....................................................................................... - 26 -
8. Website ............................................................................................................................................ - 26 -
9. Preliminary Modeling ...................................................................................................................... - 26 -
10. Fuselage ....................................................................................................................................... - 27 -
7.1 Sizing ...................................................................................................................................... - 27 -
7.2 Wing-Fuselage Connection ..................................................................................................... - 27 -
7.3 Empennage-Fuselage Connection ........................................................................................... - 28 -
7.4 Motor-Mount........................................................................................................................... - 28 -
7.5 Payload and Maintenance Accessibility .................................................................................. - 29 -
7.6 Fuselage Construction Process ................................................................................................ - 29 -
11. Empennage .................................................................................................................................. - 30 -
8.1 Tail Configuration Selection ................................................................................................... - 30 -
8.2 Horizontal Stabilizer Airfoil Selection .................................................................................... - 30 -
8.3 Horizontal and Vertical Stabilizer Sizing................................................................................ - 30 -
8.4 Empennage Position Relative to Wings .................................................................................. - 31 -
8.5 Incidence Angle ...................................................................................................................... - 31 -
12. Preliminary Testing ..................................................................................................................... - 32 -
13. Design Analysis and Review ....................................................................................................... - 32 -
10.1 Wing........................................................................................................................................ - 32 -
10.2 Wing Structural Analysis ........................................................................................................ - 39 -
10.2.1 Analysis With Design 2 .................................................................................................. - 39 -
10.3 Empennage .............................................................................................................................. - 40 -
10.4 Servo Performance .................................................................................................................. - 40 -
10.5 Weight ..................................................................................................................................... - 40 -
10.5.1 Predicted Performance ................................................................................................... - 40 -
14. Final Testing and Evaluation ....................................................................................................... - 41 -
11.1 Testing .................................................................................................................................... - 41 -
11.2 Results ..................................................................................................................................... - 42 -
11.3 Evaluation ............................................................................................................................... - 42 -
11.3.1 Engine ............................................................................................................................ - 42 -
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11.3.2 Wings ............................................................................................................................. - 42 -
11.3.3 Fuselage.......................................................................................................................... - 42 -
11.3.4 Wireless Systems............................................................................................................ - 43 -
11.3.5 Controls .......................................................................................................................... - 43 -
11.3.6 Empennage ..................................................................................................................... - 43 -
11.3.7 Landing Gear/Externals .................................................................................................. - 43 -
11.4 Evaluation Summary ............................................................................................................... - 43 -
11.5 Conclusion .............................................................................................................................. - 43 -
15. References ................................................................................................................................... - 46 -
16. Appendices .................................................................................................................................. - 49 -
13.1 Appendix A - Plans and Specs ................................................................................................ - 49 -
13.2 Appendix B - Wind Tunnel Modification and Testing ........................................................... - 50 -
13.2.1 Design Goals .................................................................................................................. - 50 -
13.2.2 Research ......................................................................................................................... - 50 -
13.2.3 Design Process ............................................................................................................... - 52 -
13.2.4 Abandonment of Modification Idea ............................................................................... - 53 -
13.2.5 Final Results ................................................................................................................... - 53 -
13.3 Appendix C - Budget and Costs .............................................................................................. - 54 -
13.4 Appendix D - Mech. Lab III (MEE 443) Report ..................................................................... - 56 -
13.4.1 Introduction .................................................................................................................... - 58 -
13.4.2 Experimental Objectives ................................................................................................ - 59 -
13.4.3 Apparatus, Equipment, and Instrumentation .................................................................. - 60 -
13.4.4 Experimental Theory ...................................................................................................... - 62 -
13.4.5 Experimental Procedure ................................................................................................. - 64 -
13.4.6 Experimental Results and Conclusions .......................................................................... - 67 -
13.4.7 Mech. Lab Appendix A: Uncertainty Level Buildup ..................................................... - 73 -
13.4.8 Mech. Lab Appendix B: Beam Calibration .................................................................... - 77 -
13.5 Appendix E - Flight Simulation Code ..................................................................................... - 78 -
13.6 Appendix F - Servo Performance MathCAD Worksheet ........................................................ - 80 -
13.7 Appendix G - Engine Specs .................................................................................................... - 82 -
13.8 Appendix H – Project Timeline .............................................................................................. - 85 -
13.9 Appendix I – Team Photograph .............................................................................................. - 86 -

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2. Table of Figures

Figure 1 - Finished Aircraft ...................................................................................................................... - 11 -
Figure 2 - Magnum XLS 0.61A ................................................................................................................ - 11 -
Figure 3 - Wing End View ....................................................................................................................... - 12 -
Figure 4 - Perspective View of Wings ...................................................................................................... - 12 -
Figure 5 - Final Fuselage; FWD End ........................................................................................................ - 12 -
Figure 6 - Fuselage FWD End with Hatch Open ...................................................................................... - 12 -
Figure 7 - Transmitter and Receiver ......................................................................................................... - 12 -
Figure 8 - Servo Illustration...................................................................................................................... - 13 -
Figure 9 - Adjustable Angle of Incidence ................................................................................................. - 13 -
Figure 10 - Completed Empennage .......................................................................................................... - 13 -
Figure 11 - Ground Stance ....................................................................................................................... - 13 -
Figure 12 - Example Cl and L/D Polars ................................................................................................... - 16 -
Figure 13 - Example Pressure Distribution .............................................................................................. - 16 -
Figure 14 - Example Data Spreadsheet .................................................................................................... - 17 -
Figure 15 - Relative Drag Contributions .................................................................................................. - 19 -
Figure 16 - Induced Drag Schematic ........................................................................................................ - 19 -
Figure 17 - Clmax vs AOA for Various AR ............................................................................................. - 20 -
Figure 18 - Stall Onset for Taper Design .................................................................................................. - 22 -
Figure 19 - Wing Edge Desing Variation ................................................................................................. - 24 -
Figure 20 - Lift Distribution Illustration ................................................................................................... - 25 -
Figure 21 - Wing SolidWorks Iso View ................................................................................................... - 27 -
Figure 22 - Wing SolidWorks End View ................................................................................................. - 27 -
Figure 23 - Hand-Built Wing Mockup ..................................................................................................... - 27 -
Figure 24 - Fuselage Spacing Model ........................................................................................................ - 27 -
Figure 25 - Aluminum Sheath w/ Dihedral .............................................................................................. - 28 -
Figure 26 - Wing Mounting Method ........................................................................................................ - 28 -
Figure 27 - Fuselage Tail Boom ............................................................................................................... - 28 -
Figure 28 - Fuselage / Tail Boom Interface .............................................................................................. - 28 -
Figure 29 - Motor Mount .......................................................................................................................... - 29 -
Figure 30 - Payload Bay Open ................................................................................................................. - 29 -
Figure 31 - Payload Bay Closed ............................................................................................................... - 29 -
Figure 32 - Wing Rib Illustration ............................................................................................................. - 29 -
Figure 33 - Empennage Diagram .............................................................................................................. - 30 -
Figure 34 - Tail Angle Adjustability ........................................................................................................ - 31 -
Figure 35 - Thrust Data Comparison ........................................................................................................ - 32 -
Figure 36- General Plan FBD ................................................................................................................... - 33 -
Figure 37 - Takeoff Simulink Schematic .................................................................................................. - 35 -
Figure 38 - Simulink Results .................................................................................................................... - 35 -
Figure 39 - Velocity Streamlines .............................................................................................................. - 36 -
Figure 40 - Boundary Layer ..................................................................................................................... - 36 -
Figure 41 - Velocity Contours .................................................................................................................. - 37 -
Figure 42 - Pressure Contours .................................................................................................................. - 37 -
Figure 43 - Turbulence ............................................................................................................................. - 38 -
Figure 44 - Airfoil Mesh. .......................................................................................................................... - 38 -
Figure 45 - FEA 3 in 1 Wing Deflection .................................................................................................. - 40 -
Figure 46 - Emergency Repairs ................................................................................................................ - 41 -
Figure 47 - Off-kilter empennage ............................................................................................................. - 42 -
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Figure 48 - Broken Landing Gear ............................................................................................................. - 42 -
Figure 49 - Current Wind Tunnel Flows .................................................................................................. - 50 -
Figure 50 - Flow Straightening Proposal .................................................................................................. - 51 -
Figure 51 - Flow Mapping Rig ................................................................................................................. - 51 -
Figure 52 - Velocity Contour at Outlet ..................................................................................................... - 52 -
Figure 53 - Flow Streamlines Through Duct ............................................................................................ - 53 -
Figure 54 - Pressure Contours Along Duct Wall ...................................................................................... - 53 -
Figure 55 - Elevation View of Experimental Setup .................................................................................. - 61 -
Figure 56 - Plan View of Experimental Setup .......................................................................................... - 62 -
Figure 57 - LabView VI Schematic .......................................................................................................... - 66 -
Figure 58 - Data Table and Plot of Static Thrust Coefficient v. RPM for APC 11x7 .............................. - 68 -
Figure 59 - Theoretical Propeller Thrust vs. RPM (APC 11x7) ............................................................... - 69 -
Figure 60 - EVO 11x7 Static Thrust vs. RPM .......................................................................................... - 70 -
Figure 61 - EVO 12x6 Static Thrust vs. RPM .......................................................................................... - 70 -
Figure 62 - K Series Master Airscrew Static Thrust vs. RPM .................................................................. - 71 -
Figure 63 - Propeller Trendline Comparison ............................................................................................ - 72 -
Figure 64 - Calibration Data Plot ............................................................................................................. - 77 -
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3. Contributions

 David Chandpen (Lead)

Wing Design, SolidWorks of the wing, assisted in other SolidWorks parts, assisted in
airfoil selection, thrust testing, project poster, construction of the aircraft.

 Zachary Veilleux

CFD Analysis, Strength Analysis, LabVIEW VI Design, Mech Lab Electronics Design &
Fabrication, Pitch Stability Analysis, Empennage Design, Laser Cutting

 Matthew Maberry

Airfoil Selection, Wing Design and Analysis including structural considerations, assisted
in empennage design and analysis, horizontal stabilizer modeling, assisted with thrust
testing, completed many aspects of Mechanical Laboratory writing, completed
empennage construction, assisted wing construction.

 Joseph Travaglini

Thrust Test LabView VI Setup, CorelDRAW Files, Laser Cutting/Manufacturing,
Assisted with Fuselage and Wing Construction, Landing Gear Research, Fuselage
Research, Class Presentations, Fall and Spring Final Reports, Assisted with Structural
Analysis

 Benjamin Waller

Project Budget and Record Keeping, Project Webpage Design and Maintenance, Wing
Mockup Construction, Fuselage Design and Construction Work, Empennage
Construction, Wing Construction, Mech. Lab Report Writing, Final Aircraft Monokoting
and Preparation

 Travis Cushman

Class PowerPoint Presentations, Original Thrust Test, Fall Semester Final Report
Writing, Formatting and Organization, Fuselage Design, Solid Modeling, MechLab Test
Rig Design/Construction, Poster, Construction/Assembly, Final Report
Writing/Formatting and Organization.
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4. Introduction Through effective analysis and research, the
group must determine which characteristics may
4.1 Project Beginnings be sacrificed in order to achieve others, and then
how to build the aircraft to achieve the desired
This project was initially conceived in a performance characteristics. Therein lies the
fundamental form near the end of the 2011-2012 challenge. No single aircraft is suited for all-
academic year. At a basic level, this capstone is around performance, and in this case need not
built on an engineering competition, the essence be.
of which is small scale powered flight. Similar
established projects were known to exist at the 4.3 MEE Capstone Project and Associated
time this undertaking was first envisaged, and it Opportunities
was hoped that an Aero Design group could be
established for students interested in aerospace The feasibility of attending the actual
and flight sciences. This was of course, competition was discussed early on in the project
successful, and the first SAE Aero Design timeline. Ultimately, it was decided that having a
project group has been formed. competitive aircraft by the competition date in
April was not guaranteed given that this group
4.2 SAE Aero Design Competition represents the first iteration from the University
of Maine, and none of the team members have
The central component of the capstone project is aeronautics experience. In order to participate in
the SAE Aero Design competition, the rules of the competition, groups must register some
which are the source of most of the project goals, months ahead of time, and by the registration
guidelines, and regulations. This is an event deadline, the prediction of successful
created and administered by the Society of competition entry was not strong enough to
Automotive Engineers, in which groups of warrant spending a large portion of the team
college level engineering students from around budget in registration fees.
the globe may participate. This event may
adequately be described as an aircraft heavy-lift However, it was also determined that that
competition. success of the project was not hinged upon the
attendance of the competition, for many reasons
Three classes are available for entry: regular, which will be cited below. The goal set forth
micro, and advanced. The class chosen by this from the beginning remains to produce a vehicle
group is the regular class. The objective of the that is “competition worthy”.
regular class is to design, substantiate, construct,
analyze, and test a remote controlled aerial To be “competition worthy” the aircraft would
vehicle of limited specifications with the need to conform to all restrictions outlined in the
capability of completing a circuit with payload official rules. A brief summary of these, for the
beyond its own weight. regular class, is as follows:

The most critical design limitations are the Maximum takeoff distance is 200 ft.
specification of engine size, the total
length/width/height of the plane, the total Maximum landing distance is 400 ft., in
possible weight, the takeoff and landing the same direction as takeoff
distances, and to some degree, the materials
allowed in construction. Creating an aircraft Aircraft must me heavier than air, fixed
based on these restrictions while maintaining the wing construction
ability to lift enough payload to effectively
compete requires evaluation of design tradeoffs Total combined length measurement not
and development of a very specialized exceeding 225 in.
configuration. Focus must be maintained on the
assembly of components such that the vehicle Gross weight restricted to 55 lb.
will be simultaneously stable, structurally sound,
and task-effective. Prohibition of fiber reinforced plastics
and use of lead

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