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Flexible all-plastic aircraft models built by additive manufacturing for transonic wind tunnel tests

机译：通过增材制造为跨音速风洞测试构建的灵活的全塑料飞机模型

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摘要

Wind tunnel testing is considered as a reliable tool, especially for the high-order non-linear aerodynamic problems of large aircraft with high-aspect-ratio wings at transonic speeds. Thanks to its capacity to manufacture complex structures quickly, the introduction of the additive manufacturing (AM) technique into the design and fabrication of testing models can improve the testing performance significantly. However, these AM-built models so far are limited to low-speed testing due to the low strength and modulus of non-metal materials, epoxy resins mostly, used in popular AM processes for aircraft models. The easy-deformation properties are usually considered as the major weakness and many methods are adopted to strengthen the plastic models for high speed tests. Taking advantage of the properties, however, this paper proposes a plastic flexible testing model with a specific pre-deformation that can be deformed into the desired state during wind tunnel tests. To obtain the pre-deformation quantitatively, an optimization formulation was developed based on the coupling of computational fluid dynamics (CFD) and computational structural dynamics (CSD). As a case study, testing models with the DLR (German Aerospace Center) F4 configuration were designed and fabricated by stereolithography (SL), a popular AM process. After the strength calibration, the plastic models were tested in a transonic wind tunnel. All the models performed normally in the harsh condition when the Mach number reached 0.85, and the resulting lift coefficients (C-L) obtained by the plastic models showed good consistence with their metallic counterparts. This indicates that the plastic models of large aircraft made by SL could be used in wind tunnel tests at transonic speeds. However, the all plastic models can only be used in a single combination of testing condition. Further studies should be conduct to extend the scope of application of the models. In conclusion, due to AM's capacity to manufacture complex structures with low-modulus materials, flexible models could be designed and built quickly in an economic way. The method could be used in the conceptual design for configuration screening of high-aspect-ratio aircraft, and the paper would provide a new test scheme that is fast and reliable for aircraft design. (C) 2018 Elsevier Masson SAS. All rights reserved.
机译：风洞测试被认为是一种可靠的工具，特别是对于跨音速下具有高长宽比机翼的大型飞机的高阶非线性空气动力学问题。由于具有快速制造复杂结构的能力，将增材制造（AM）技术引入测试模型的设计和制造中可以显着提高测试性能。但是，由于非金属材料（大多数是环氧树脂）的低强度和模量低，目前为止，这些AM内置模型仅限于低速测试，而这种非金属材料通常用于飞机模型的AM过程中。易变形特性通常被认为是主要弱点，并且采用了许多方法来强化用于高速测试的塑性模型。然而，利用这些特性，本文提出了一种具有特定预变形的塑料柔性测试模型，该模型在风洞测试期间可以变形为所需状态。为了定量地获得预变形，基于计算流体动力学（CFD）和计算结构动力学（CSD）的耦合，开发了优化公式。作为案例研究，采用流行的AM工艺立体光刻（SL）设计和制造了具有DLR（德国航空航天中心）F4配置的测试模型。强度校准后，在跨音速风洞中测试塑料模型。当马赫数达到0.85时，所有模型都在恶劣条件下正常运行，并且通过塑性模型获得的最终升力系数（C-L）与金属模型具有良好的一致性。这表明SL制造的大型飞机的塑料模型可以在跨音速下进行风洞测试。但是，所有塑料模型只能在单个测试条件下使用。应该进行进一步的研究以扩展模型的应用范围。总之，由于AM能够使用低模量材料制造复杂的结构，因此可以以经济的方式快速设计和构建灵活的模型。该方法可用于高长宽比飞机的构型筛选的概念设计中，为飞机设计提供一种快速，可靠的测试方案。 （C）2018 Elsevier Masson SAS。版权所有。

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  • 来源
    《Aerospace science and technology》 |2019年第1期|237-244|共8页
  • 作者

    Zhu Weijun; Zhang Xiaoyu; Li Dichen;

  • 作者单位

    Xi An Jiao Tong Univ, State Key Lab Mfg Syst Engn, Xian 710049, Shaanxi, Peoples R China|Xi An Jiao Tong Univ, Collaborat Innovat Ctr High End Mfg Equipment, Xian 710049, Shaanxi, Peoples R China;

    Xi An Jiao Tong Univ, State Key Lab Mfg Syst Engn, Xian 710049, Shaanxi, Peoples R China|Xi An Jiao Tong Univ, Collaborat Innovat Ctr High End Mfg Equipment, Xian 710049, Shaanxi, Peoples R China;

    Xi An Jiao Tong Univ, State Key Lab Mfg Syst Engn, Xian 710049, Shaanxi, Peoples R China;

  • 收录信息 美国《科学引文索引》(SCI);美国《工程索引》(EI);
  • 原文格式 PDF
  • 正文语种 eng
  • 中图分类
  • 关键词

    Wind tunnel; Aerodynamics; Additive manufacturing; Stereolithography; Optimization;

    机译：风洞;空气动力学;增材制造;立体光刻;优化;

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