Design of a large-scale model for wind tunnel test of a multiadaptive flap concept

The design and application of morphing systems are ongoing issues compelling the aviation industry.The Clean Sky-program represents the most significant aeronautical research ever launched in Europe on advanced technologies for greening next-generation aircraft.The primary purpose of the program is to develop new concepts aimed at decreasing the effects of aviation on the environment,increasing reliability,and promoting eco-friendly mobility.These ambitions are pursued through research on enabling technologies fostering noise and gas emissions reduction,mainly by improving aircraft aerodynamic performances.Within the Clean Sky framework,a multimodal morphing flap device was designed based on tight industrial requirements and tailored for large civil aircraft applications.The flap is deployed in one unique setting,and its cross section is morphed differently in take-off and landing to get the necessary extra lift for the specific flight phase.Moreover,during the cruise,the tip of the flap is deflected for load control and induced drag reduction.Before manufacturing the first flap prototype,a high-speed(Ma=0.3),large-scale test campaign(geometric scale factor 1:3)was deemed necessary to validate the performance improvements brought by this novel system at the aircraft level.On the other hand,the geometrical scaling of the flap prototype was considered impracticable due to the unscalability of the embedded mechanisms and actuators for shape transition.Therefore,a new architecture was conceived for the flap model to comply with the scaled dimensions requirements,withstand the relevant loads expected during the wind tunnel tests and emulate the shape transition capabilities of the true-scale flap.Simplified strategies were developed to effectively morph the model during wind tunnel tests while ensuring the robustness of each morphed configuration and maintaining adequate stiffness levels to prevent undesirable deviations from the intended aerodynamic shapes.Additionally,a simplified design was conceived for the flap-wing interface,allowing for quick adjustments of the flap setting and enabling load transmission paths like those arising between the full-scale flap and the wing.The design process followed for the definition of this challenging wind tunnel model has been addressed in this work,covering the definition of the conceptual layout,the numerical evaluation of the most severe loads expected during the test,and the verification of the structural layout by means of advanced finite element analyses.

Aerodynamic optimization of an adaptive flap for next-generation green aircraft

Adaptive,morphing flaps are taking ever-increasing attention in civil aviation thanks to the expected benefits this technology can bring at the aircraft level in terms of high-lift performance improvement and related fuel burnt reduction per flight.Relying upon morphing capabilities,it is possible to fix a unique setting for the flap and adapt the flap shape to match the aerodynamic requirements for take-off or landing.The proper morphed shapes can assure better high-lift performances than those achievable by referring to a conventional flap.Moreover,standing the unique flap setting for take-off and landing,a dramatic simplification of the flap deployment systems may be achieved.As a consequence of this simplification,the deployment system can be fully hosted in the wing,thus avoiding under-wing nacelles with significantly better aerodynamics and fuel consumption.The first step for a rational design of an adaptive flap consists in defining the target morphed shapes and the unique optimal flap setting in the take-off and landing phases.In this work,aerodynamic optimization analyses are carried out to determine the best flap setting and related morphed shapes in compliance with the take-off and landing requirements of a reference civil transport aircraft.Four different initial conditions are adopted to avoid the optimization falling into local optima,thus obtaining four groups of optimal candidate configurations.After comparing each candidate’s performance through 2D and 3D simulations,the optimal configuration has been selected.2D simulations show that the optimal configuration is characterized by a maximum lift increase of 31.92%in take-off and 9.04%in landing.According to 3D simulations,the rise in maximum lift equals 22.26%in take-off and 3.50%in landing.Numerical results are finally verified through wind tunnel tests,and the aerodynamic mechanism behind the obtained improvements is explained by carefully analyzing the flow field around the flap.

Morphing wing flaps for large civil aircraft:Evolution of a smart technology across the Clean Sky program

Abstract Morphing wing structures are widely considered among the most promising technologies for the improvement of aerodynamic performances in large civil aircraft.The controlled adaptation of the wing shape to external operative conditions naturally enables the maximization of aircraft aerodynamic efficiency,with positive fallouts on the amount of fuel burned and pollutant emissions.The benefits brought by morphing wings at aircraft level are accompanied by the criticalities of the enabling technologies,mainly involving weight penalties,overconsumption of electrical power,and safety issues.The attempt to solve such criticalities passes through the development of novel design approaches,ensuring the consolidation of reliable structural solutions that are adequately mature for certification and in-flight operations.In this work,the development phases of a multimodal camber morphing wing flap,tailored for large civil aircraft applications,are outlined with specific reference to the activities addressed by the author in the framework of the Clean Sky program.The flap is morphed according to target shapes depending on aircraft flight conditions and defined to enhance high-lift performances during takeoff and landing,as well as wing aerodynamic efficiency during cruise.An innovative system based on finger-like robotic ribs driven by electromechanical actuators is proposed as morphing-enabling technology;the maturation process of the device is then traced from the proof of concept to the consolidation of a true-scale demonstrator for pre-flight ground validation tests.A step-by-step approach involving the design and testing of intermediate demonstrators is then carried out to show the compliance of the adaptive system with industrial standards and safety requirements.The technical issues encountered during the development of each intermediate demonstrator are critically analyzed,and justifications are provided for all the adopted engineering solutions.Finally,the layout of the true-scale demonstrator is presented,with emphasis on the architectural strengths,enabling the forthcoming validation in real operative conditions.