Aeroelastic Tailoring via Tow Steered Composites

The use of tow steered composites, where fibers follow prescribed curvilinear paths within a laminate, can improve upon existing capabilities related to aeroelastic tailoring of wing structures, though this tailoring method has received relatively little attention in the literature. This paper demonstrates the technique for both a simple cantilevered plate in low-speed flow, as well as the wing box of a full-scale high aspect ratio transport configuration. Static aeroelastic stresses and dynamic flutter boundaries are obtained for both cases. The impact of various tailoring choices upon the aeroelastic performance is quantified: curvilinear fiber steering versus straight fiber steering, certifiable versus noncertifiable stacking sequences, a single uniform laminate per wing skin versus multiple laminates, and identical upper and lower wing skins structures versus individual tailoring

Survey of Applications of Active Control Technology for Gust Alleviation and New Challenges for Lighter-weight Aircraft

This report provides a historical survey and assessment of the state of the art in the modeling and application of active control to aircraft encountering atmospheric disturbances in flight. Particular emphasis is placed on applications of active control technologies that enable weight reduction in aircraft by mitigating the effects of atmospheric disturbances. Based on what has been learned to date, recommendations are made for addressing gust alleviation on as the trend for more structurally efficient aircraft yields both lighter and more flexible aircraft. These lighter more flexible aircraft face two significant challenges reduced separation between rigid body and flexible modes, and increased sensitivity to gust encounters due to increased wing loading and improved lift to drag ratios. The primary audience of this paper is engineering professionals new to the area of gust load alleviation and interested in tackling the multifaceted challenges that lie ahead for lighter-weight aircraft

Trim and Structural Optimization of Subsonic Transport Wings Using Nonconventional Aeroelastic Tailoring

Several minimum-mass aeroelastic optimization problems are solved to evaluate the effectiveness of a variety of novel tailoring schemes for subsonic transport wings. Aeroelastic strength and panel buckling constraints are imposed across a variety of trimmed maneuver loads. Tailoring with metallic thickness variations, functionally graded materials, composite laminates, tow steering, and distributed trailing edge control effectors are all found to provide reductions in structural wing mass with varying degrees of success. The question as to whether this wing mass reduction will offset the increased manufacturing cost is left unresolved for each case

Aeroelastic Tailoring of Transport Wings Including Transonic Flutter Constraints

Several minimum-mass optimization problems are solved to evaluate the effectiveness of a variety of novel tailoring schemes for subsonic transport wings. Aeroelastic stress and panel buckling constraints are imposed across several trimmed static maneuver loads, in addition to a transonic flutter margin constraint, captured with aerodynamic influence coefficient-based tools. Tailoring with metallic thickness variations, functionally graded materials, balanced or unbalanced composite laminates, curvilinear tow steering, and distributed trailing edge control effectors are all found to provide reductions in structural wing mass with varying degrees of success. The question as to whether this wing mass reduction will offset the increased manufacturing cost is left unresolved for each case

Sizing and Layout Design of an Aeroelastic Wingbox Through Nested Optimization

The goals of this work are to 1) develop an optimization algorithm that can simultaneously handle a large number of sizing variables and topological layout variables for an aeroelastic wingbox optimization problem and 2) utilize this algorithm to ascertain the benefits of curvilinear wingbox components. The algorithm used here is a nested optimization, where the outer level optimizes the rib and skin stiffener layouts with a surrogate-based optimizer, and the inner level sizes all of the components via gradient-based optimization. Two optimizations are performed: one restricted to straight rib and stiffener components only, the other allowing curved members. A moderate 1.18% structural mass reduction is obtained through the use of curvilinear members

Aeroelastic Tailoring of the NASA Common Research Model via Novel Material and Structural Configurations

This work explores the use of tow steered composite laminates, functionally graded metals (FGM), thickness distributions, and curvilinear rib/spar/stringer topologies for aeroelastic tailoring. Parameterized models of the Common Research Model (CRM) wing box have been developed for passive aeroelastic tailoring trade studies. Metrics of interest include the wing weight, the onset of dynamic flutter, and the static aeroelastic stresses. Compared to a baseline structure, the lowest aggregate static wing stresses could be obtained with tow steered skins (47% improvement), and many of these designs could reduce weight as well (up to 14%). For these structures, the trade-off between flutter speed and weight is generally strong, although one case showed both a 100% flutter improvement and a 3.5% weight reduction. Material grading showed no benefit in the skins, but moderate flutter speed improvements (with no weight or stress increase) could be obtained by grading the spars (4.8%) or ribs (3.2%), where the best flutter results were obtained by grading both thickness and material. For the topology work, large weight reductions were obtained by removing an inner spar, and performance was maintained by shifting stringers forward and/or using curvilinear ribs: 5.6% weight reduction, a 13.9% improvement in flutter speed, but a 3.0% increase in stress levels. Flutter resistance was also maintained using straightrotated ribs although the design had a 4.2% lower flutter speed than the curved ribs of similar weight and stress levels were higher. These results will guide the development of a future design optimization scheme established to exploit and combine the individual attributes of these technologies

Static Loads Testing of a High Aspect Ratio Tow-Steered Wingbox

Static loads testing was performed on a 39-foot, high-aspect-ratio wingbox comprising carbon fiber tow-steered wing skins that were tailored for aircraft fuel efficiency under aeroelastic loads. The test article was designated the Passive Aeroelastic Tailored (PAT) wing. To date, the PAT wing, which has an aspect ratio of 13.5, is the largest wingbox designed and built to employ variably oriented carbon fibers along the span of the wing. During testing, distributed point loads were applied to the wingbox to simulate both -1g and 2.5g maneuver loads. To determine the wingboxs flexural axis location, individual point loads were applied. The global response of the wing (displacement and rotation measurements) showed similar trends compared to the finite element model predictions, though discrepancies of up to 17% were observed when comparing actual values between model and test. It was concluded that the boundary conditions and nonstructural features of the wingbox were the likely cause of the inconsistencies. The local response of the wingbox (strain measurements), which was much less affected by factors unrelated to tow-steering, exhibited good agreement with the model predictions, validating the modelling techniques employed for tow-steered composites

A Framework for Optimal Control Allocation with Structural Load Constraints

Conventional aircraft generally employ mixing algorithms or lookup tables to determine control surface deflections needed to achieve moments commanded by the flight control system. Control allocation is the problem of converting desired moments into control effector commands. Next generation aircraft may have many multipurpose, redundant control surfaces, adding considerable complexity to the control allocation problem. These issues can be addressed with optimal control allocation. Most optimal control allocation algorithms have control surface position and rate constraints. However, these constraints are insufficient to ensure that the aircraft's structural load limits will not be exceeded by commanded surface deflections. In this paper, a framework is proposed to enable a flight control system with optimal control allocation to incorporate real-time structural load feedback and structural load constraints. A proof of concept simulation that demonstrates the framework in a simulation of a generic transport aircraft is presented

Aeroelastic tailoring of a plate wing with functionally graded materials

This work explores the use of functionally graded materials for the aeroelastic tailoring of a metallic cantilevered plate-like wing. Pareto trade-off curves between dynamic stability (flutter) and static aeroelastic stresses are obtained for a variety of grading strategies. A key comparison is between the effectiveness of material grading, geometric grading (i.e., plate thickness variations), and using both simultaneously. The introduction of material grading does, in some cases, improve the aeroelastic performance. This improvement, and the physical mechanism upon which it is based, depends on numerous factors: the two sets of metallic material parameters used for grading, the sweep of the plate, the aspect ratio of the plate, and whether the material is graded continuously or discretely

Deformed Shape Calculation of a Full-Scale Wing Using Fiber Optic Strain Data from a Ground Loads Test

A ground loads test of a full-scale wing (175-ft span) was conducted using a fiber optic strain-sensing system to obtain distributed surface strain data. These data were input into previously developed deformed shape equations to calculate the wing s bending and twist deformation. A photogrammetry system measured actual shape deformation. The wing deflections reached 100 percent of the positive design limit load (equivalent to 3 g) and 97 percent of the negative design limit load (equivalent to -1 g). The calculated wing bending results were in excellent agreement with the actual bending; tip deflections were within +/- 2.7 in. (out of 155-in. max deflection) for 91 percent of the load steps. Experimental testing revealed valuable opportunities for improving the deformed shape equations robustness to real world (not perfect) strain data, which previous analytical testing did not detect. These improvements, which include filtering methods developed in this work, minimize errors due to numerical anomalies discovered in the remaining 9 percent of the load steps. As a result, all load steps attained +/- 2.7 in. accuracy. Wing twist results were very sensitive to errors in bending and require further development. A sensitivity analysis and recommendations for fiber implementation practices, along with, effective filtering methods are include