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Manufacturing of Small Air Craft-Study Model PDF
Manufacturing of Small Air Craft-Study Model PDF
A final Project
BACHELOR OF TECHNOLOGY
In
PPSU
CONTENTS
DESCRIPTION PG.NO
ABSTRACT
1.0. Introduction
2.0. Literature Review
3.0. Airfoil Theory
3.1 Lift
3.2 Drag
4.0. Basic design in Fabrication of air craft
4.1 Wing
4.2 Aspect ratio
4.3 Wing Taper
4.4 Incidence angle
4.5 Tail `
4.6 Tail shape
4.7. Tail Size
5.0. Fabrication of a small aircraft
5.1 Making of MAIN BODY
5.2 Making of WING
5.3 Making of TAIL
6.0. Electronics used in Aircraft
6.1 Transmitter
6.2 Receiver
6.3 ESC (Electronic Speed Controller)
6.4 Battery
6.5 Motor
6.6 Servo Motor
6.7 Connections
7.0. Design calculations of Aircraft
7.1 calculations of coefficient of Drag and Lift
7.2 Comparison on between coefficient of Drag and Lift
7.3 Calculation of Thrust power
7.4 Design specification of a Aircraft
7.5 Coefficient of Lift
7.6 .Coefficient of Drag
8.0. Comparison Between angle attack VS Lift and Drag
9.0. Conclusions
10.0. Reference
LIST OF FIGURES :
1. Basic parts of a simple aircraft
2. Demonstration of Lift and Drag of an Airplane
3. Aspect ratio variation
4. Angle of attack is the line a wing
5. Tail of an Aircraft
6. Fabrication of air craft body frame
7. Fabrication of air craft wing
8. The total fabricated proto type air craft
ABSTRACT
An attempt has been made to study the basic design calculation of the simple aircraft.
The effects of the different components of the aircraft on total weight, flight, propulsion, lift
and drag has been studied. Small prototype aircraft fabrication has been completed going
through the literature review. The aesthetic shape of the aircraft has been obtained following
the design procedures. The propulsion and flight of aircraft is also verified by trails. Further
attempts are required to complete the aerodynamic and flight dynamic aspects of the
fabricated prototype aircraft.
CHAPTER 1
INTRODUCTION
The aircraft design process is the engineering design process by which those are
designed. These depend on many factors such as customer and manufacturer demand, safety
protocols, physical and economic constraints etc. For some types of aircraft the design process
is regulated by national airworthiness authorities.
Aircraft design normally starts with initial design with consideration of all the
constraints on their design. It needs to follow certain basic laws to design or fabricate these
devices. The technology has emerged to a state of art following the decades of advancements
in terms of lower weight and improved flight conditions. However there is a complexity in
design and development of high Mach number air vehicles.
Modern military and airline design projects are of such a large scale that every design
aspect is tackled by different teams and then brought together. This mini project wo deals with
the simple steps involved in modeling, design and fabrication of small aircraft. Since the basic
scientific phenomena are same irrespective of size of aircraft, however there would be
considerable interception in optimization of several aerodynamic aspects. Each component
design of these vehicles has been developed as the streams of research. This works aims at
overview of basic components which can show case some aspects. The key components of a
basic aircraft are shown below.
Fig.1. Basi
Basic parts of a simple aircraft
Saida reddy et al [2] studied creative process of aircraft design is driven by the needs and
opportunities of the future market. From these needs, covering the requirements from the entire air
transport system, specific targets are to be derived. Referring to today's products new designs are
subsequently generated, aiming to meet the targets anticipated. Experience has shown that a significant
gap will probably appear between the status and the desired targets. Besides design aspects such as the
a/c capacity and range, the development of new technologies is mandatory to minimize or even
eliminate the width of the gap, thus ensuring the achievement of future market demands by new
aircraft designs.
Gopi et al. [3] have presented an overview of how an airline or lesser selects an aircraft for
their fleet and how a manufacturer decides what aircraft to produce. Each of these industries are
extremely capital intensive and have different goals and success measures. This creates a dynamic and
competitive market where aircraft selection decisions have the potential to either propel or bankrupt a
firm. Understanding the wants and needs of airlines, lessors, and manufactures will lead to a greater
understanding of effective aircraft.
Based on the above literature review and motivation it is planned to work for fabrication of a
prototype aircraft and also to conduct the performance and stability analysis of the fabricated aircraft.
Chapter-3
Aerofoil Theory
3.0. Introduction to Aerofoil Theory
This chapter will brief about the importance of airfoil section of the wings of the aircraft
which are responsible for giving lift. The main components of the propulsion being the
propeller shaft; however the flight controls are made by the effective design of airfoil shapes
of the aircraft. Some basic definitions in aerodynamics are presented here. The theory of
airfoil intended to better design of the airfoil shapes.
An airfoil-shaped body moved through a fluid produces an aerodynamic force. The
component of this force perpendicular to the direction of motion is called lift. The component
parallel to the direction of motion is called drag. Subsonic flight airfoils have a characteristic
shape with a rounded leading edge, followed by a sharp trailing edge, often with
a symmetric curvature of upper and lower surfaces. Foils of similar function designed with
water as the working fluid are called hydrofoils.
3.1 Lift :
The basic definition of lift is, it is perpendicular to the free - stream air flow direction.
Lift is the force that directly opposes the weight of an airplane and holds the airplane
in the air. Lift is generated by every part of the airplane, but most of the lift on a normal
airliner is generated by the wings. Lift is a mechanical aerodynamic force produced by the
motion of the airplane through the air. Because lift is a force, it is a vector quantity, having
both a magnitude and a direction associated with it. Lift acts through the center of pressure of
the object and is directed perpendicular to the flow direction. There are several factors which
affect the magnitude of lift.
Lift occurs when a moving flow of gas is turned by a solid object. The flow is turned
in one direction, and the lift is generated in the opposite direction, according to Newton's
Third Law of action and reaction. Because air is a gas and the molecules are free to move
about, any solid surface can deflect a flow. For an aircraft wing, both the upper and lower
surfaces contribute to the flow turning. Neglecting the upper surface's part in turning the flow
leads to an incorrect theory of lift.
The lift force produced by a wing, L, is
L = ×ρ× ×A×CL
Where
ρ is the density of the surrounding air,
v is the true airspeed,
A is the platform area, and
CL is the coefficient of lift. The coefficient of lift is a number that determines the lift
produced based on the geometry, or shape, of the wing. This number changes with
different angles of attack, and also with changes in speed or air conditions.
3.2 Drag :
The basic definition of drag is, it is the parallel to the air free –stream air flow direction.
Drag is a mechanical force. It is generated by the interaction and contact of a solid
body with a fluid (liquid or gas). It is not generated by a force field, in the sense of
a gravitational field or an electromagnetic field, where one object can affect another object
without being in physical contact. For drag to be generated, the solid body must be in contact
with the fluid. If there is no fluid, there is no drag. Drag is generated by the difference in
velocity between the solid object and the fluid. There must be motion between the object and
the fluid. If there is no motion, there is no drag. It makes no difference whether the object
moves through a static fluid or whether the fluid moves past a static solid object.
Drag is a force and is therefore a vector quantity having both a magnitude and a
direction. Drag acts in a direction that is opposite to the motion of the aircraft. Lift acts
perpendicular to the motion. There are many factors that affect the magnitude of the drag.
Many of the factors also affect lift but there are some factors that are unique to aircraft drag.
To reduce complexity and to avoid drag increases in cruise, the aircraft will be
manufactured without conventional flaps. If it is found necessary to increase CL for
landing or take-off, the aileron surfaces could be drooped or a simple leading edge device
used. These possibilities will not be considered in the initial layout. Assuming a cambered
supercritical wing profile is used, the two-dimensional max. lift coefficient may be 1.65 for
our high aspect ratio clean wing.
Where
ρ is the density of the surrounding air,
v is the true airspeed,
A is the platform area, and
CD is the coefficient of drag. The coefficient of drag is a number that determines the
lift produced based on the geometry, or shape, of the wing. This number changes with
different angles of attack, and also with changes in speed or air conditions.
The lift and drag applications are shown in Fig.2.
Wings produce more lift when they are at a higher angle of attack. If an airfoil is curved, then the wing
will still produce some lift when the angle of attack is zero, but if it is symmetrical it will not produce
any lift. This is why vertical tails usually have symmetrical airfoils, as these will not try to turn the
plane when it flies in a straight line.
4.5Tail:
The tail of a plane is a lot smaller than the wing, but it’s just as important. Tails provide
stability, allowing planes to fly smoothly and easily through the air. The tail of an aircraft is
shown in Fig.5.
Tails are usually located at the back of the plane, rather than partway through the fuselage,
because tails are more effective the further back they are. The airplane has a point called the
centre of gravity need to know is that it’s usually in the front half of the plane, and whenever
the aircraft turns, whether it’s rolling, turning or climbing, it turns around this point. If plane
like a see saw, the centre of gravity is the pivot point of the see saw, which is the fixed point
in the middle that the see saw rotates around. Now, when two people play on a see saw and
want to balance it, the heavier person sits closer to the pivot. This is because the further away
from the pivot you get, the greater effect you’ll have on the see saw. Because tails are used to
steer the whole aircraft, it want them to have the biggest effect possible. By locating them at
the back of the aircraft, it will be as far away as possible from the centre of gravity. That way,
when the elevator creates a lift force, it will have a large effect on the plane and it will rotate
quicker. It’s also worth noting that a small tail a long way back from the centre of gravity is
equivalent to a large tail close to the centre of gravity, but a small tail will generate less drag.
Vertical tails must be at the back of the plane.
Horizontal tails can be at the front, but it’s easier to put them at the back.
The tail should be as far from the centre of gravity as possible, which usually means
the back of the plane.
4.6 Tail shape:
The shape of the tail is fairly similar to the wing. Aircraft tail design is a complex process, and
often the shape, size and position of the tail will change a few times during the design process.
As a general rule, horizontal tails have a lower aspect ratio than the aircraft’s wing.
This means they are shorter and fatter. An aspect ratio between 3 and 5 is a good place to start.
The taper ratio of the horizontal tail can be similar to the wing, between 0.3 and 0.6 is a good
place to start but feel free to use more or less. Draw a tail that you like the look of, then check
what its aspect ratio and taper ratio are, and only change it if it’s a long way outside the ranges
above. Vertical tails have even lower aspect ratios, generally between 1 and 2 but they can be
lower than 1, meaning the tail is longer than it is tall. It can be hard to judge the aspect ratio of
a tail, especially on the ACE where the tail is curved, so just gu
guess.
ess. As long as the tail’s not a
lot longer than it is wide it should be ok. Guidelines for taper ratio are the same as for the
horizontal tail, between 0.3 and 0.6 is good.
Fig.5.Tail of an Aircraft
5.0.Fabrication of a small aircraft
Motivated by the concepts of design and through the ideas gained from the literature review
the fabrication of the simple aircraft is made.
5.1 Making of MAIN BODY:
Making of body of air craft is done by light weight wood, the wood is cut by laser
machine. It is taken nearly 14 hours to make the body. The shape is taken from the air craft
models of Wikipedia. The reason behind the selection of wood as material is it is light weight
and easy to make. The body is made as a frame instead of a solid one toreduce the weight. The
whole body is given an outer finishing. The fabricated body is shown in Fig.6.
Wing is made by the same wood and its shape also done on a laser cutting machine.
Generally the wing is the primary thing of this air craft, since the size of the air craft depends
on the wing. The main body length is 75 percentage of the wing length. This wing has two
servo motors which control the direction of the plane i.e. the air craft’stake off and landing
operations. This servo motors are run by the battery and are connected to the receiver and are
control by the remote. The fabricated wing is shown in Fig.7.
Fig: Transmitter
6.2 Receiver:
Electronic unit that rides in the aircraft. Receives signals from the transmitter and relays
these signals to the servos.
Fig : Receiver
6.3 ESC (Electronic Speed Controller):
An electronic speed control or ESC is an electronic circuit that controls and regulates the
speed of an electric motor. It may also provide reversing of the motor and dynamic braking.
Miniature electronic speed controls are used in electrically powered radio controlled models.
Full-size electric vehicles also have systems to control the speed of their drive motors.
ESC. An Electronic Speed Controller does several things. First, it converts your
battery voltage down to 5v which is when receiver runs off if. Not all speed controllers have
this capability.
The second thing the ESC does is it converts the DC power from your battery to an AC
current which is required by the motor. Brushless motors run off of AC current.
An electronic speed control follows a speed reference signal (derived from a throttle
lever, joystick, or other manual input) and varies the switching rate of a network of field effect
transistors . By adjusting the duty cycle or switching frequency of the transistors, the speed of
the motor is changed. The rapid switching of the transistors is what causes the motor itself to
emit its characteristic high-pitched whine, especially noticeable at lower speeds.
Different types of speed controls are required for brushed DC motors and brushless
DC motors. A brushed motor can have its speed controlled by varying the voltage on its
armature. (Industrially, motors with electromagnet field windings instead of permanent
magnets can also have their speed controlled by adjusting the strength of the motor field
current.) A brushless motor requires a different operating principle. The speed of the motor is
varied by adjusting the timing of pulses of current delivered to the several windings of the
motor.
The correct phase varies with the motor rotation, which is to be taken into account by
the ESC: Usually, back EMF from the motor is used to detect this rotation, but variations exist
that use magnetic (Hall effect) or optical detectors. Computer-programmable speed controls
generally have user-specified options which allow setting low voltage cut-off limits, timing,
acceleration, braking and direction of rotation. Reversing the motor's direction may also be
accomplished by switching any two of the three leads from the ESC to the motor.
Fig: ESC
6.4 Battery:
Batteries have different characteristics but Li Po Battery is suitable for air craft.
The first thing to talk about is the battery's voltage. While the batteries exact voltage
may not be printed on the battery itself but it will tell how many cells the battery has. Li Po
batteries are made up of cells. Each cell is 3.7 volts. for example the battery shown above is a
2s battery. This means that is has 2 cells, which would give it a total voltage of 7.4 volts.
These cells fully discharged should NOT go below 3.3 volts and the cells fully charged should
not go 4.21 volts.
An electric aircraft is an aircraft powered by electric motors. Electricity may be
supplied by a variety of methods including batteries, ground power cables, solar cells, ultra
capacitors, fuel cells and power beaming.
Batteries are the most common energy carrier component of electric aircraft, due to
their relatively high capacity. Batteries were the earliest source of electricity, first powering
airships in the nineteenth century. These early batteries were very heavy and it was not until
the arrival of technologies such as nickel-cadmium (NiCad) rechargeable types in the second
half of the twentieth century, that batteries became a practicable power source. Modern battery
types include lithium-based and a number of other less widely used technologies. Such
batteries remain a popular power source today, although they still have limited life between
charges and hence limited range.
Fig: Battery
6.5 Motor:
The motor is the power plant of a plane. The motor will turn propeller at a high speed to
propel it through the air. standard motor that used in plane is brushless, which means it runs
off of AC current. This is it need a speed controller to convert the battery's DC power into AC.
DC electric motor (BLDC motors, BL motors) also known as electronically commutated
motors (ECMs, EC motors), or synchronous DC motors, are synchronous motors powered
by DC electricity via an inverter or switching power supply which produces an AC electric
current to drive each phase of the motor via a closed loop controller. The controller
provides pulses of current to the motor windings that control the speed and torque of the
motor.
When choosing a motor there are two basic things need to look for.
RPM. The motor above runs at 1400 KV. KV means that for every volt applied motor
will spin 1400 times. If it need a 2s battery (7.4v) then the motor's RPM is 10,360 ( 1400Kv x
7.4v = 10,360 rpm).
Power rating. The motor below is 52 watts. In order to find the wattage of the motor
multiply the max current of the motor by the voltage applied to it. This motor pulls 7 amps
and uses a 2s battery (7.4v) so 7 x 7.4 = 51.8W.
The advantages of a brushless motor over brushed motors are high power to weight
ratio, high speed, and electronic control. Brushless motors find applications in such places as
computer peripherals (disk drives, printers), hand-held power tools, and vehicles ranging from
model aircraft to automobiles.
An electric motor develops torque by alternating the polarity of rotating electromagnets
attached to the rotor, the rotating part of the machine, and stationary magnets on the stator which
surrounds the rotor. One or both sets of magnets are electromagnets, made of a coil of wire wound
around an iron core. DC running through the wire winding creates the magnetic field, providing the
power which runs the motor. However, each time the rotor rotates by 180° (a half-turn), the position of
the north and south poles on the rotor are reversed. If the magnetic field of the poles remained the
same, this would cause a reversal of the torque on the rotor each half-turn, and so the average torque
would be zero and the rotor would not turn. Therefore, in a DC motor, in order to create torque in one
direction, the direction of electric current through the windings must be reversed with every 180° turn
of the rotor (or turned off during the time that it is in the wrong direction). This reverses the direction
of the magnetic field as the rotor turns, so the torque on the rotor is always in the same direction.
Fig: Motor
6.6 Servo Motors:
Servos (also RC servos) are small, cheap, mass-produced servomotors or other actuators used
for radio control and small-scale robotics.
Most servos are rotary actuators although other types are available. Linear
actuators are sometimes used, although it is more common to use a rotary actuator with a bell
crank and pushrod. Some types, originally used as sail winches for model yachting, can rotate
continuously.
A typical servo consists of a small electric motor driving a train of reduction gears.
A potentiometer is connected to the output shaft. Some simple electronics provide a closed-
loop servomechanism.
Fig: Servo Motor
6.7 Connections:
Make sure when connect anything to the receiver that push in the servo leas so that the
brown wire (negative) faces AWAY from the text on the receiver.
Fig: Connections
7.0
.0 Design calculations of Prototype Air craft:
7.1
.1 calculations of coefficient of Drag and Lift:
Force, F=20 N, Surface Area=0.3 m2, Density ρ=490 kg/m3
Calculation of Coefficient of Lift
CL= 2FL/ρv2A, CD= 2FD/
2FD/ρv2A
1 10 0.05
2 15 0.1125
3 20 0.2
4 25 0.3125
5 30 0.45
6 35 0.6125
7 40 0.8
7.4. Design specification of a Aircraft:
Table: specifications of Aircraft
PARAMETERS VALUES
Maximum take of weight 2kg
Empty weight 1.5 kg
Length 1055 mm
Thrust weight ratio 2.5 kg
Wing span 1500 mm
Vertical stabilizer 200 mm
Type of battery 4 cell 2250 mAh
Horizontal stabilizer 600 mm
Motor size 0.5 HP
Range 700 m
Flow of air is considered to be incompressible and subsonic. The free stream air flow has been
kept 20 m/sec and the effect of temperature has been neglected. The density of air is 1.225
kg/m3. The operating pressure is 1.01 bar. The absolute viscosity is 1.789 * 10-5kg/m-s. The
data have been obtained at different angle of attack from -30 to 150 with 30 steps.
7.5. Coefficient of lift:
0 0.007755
3 0.21
6 0.41
9 0.6072
12 0.8064
15
1.0532
7.6 .Coefficient of drag:
The variation of lift co-efficient with angle of attack at 20m/sec at different angle of attack is
shown in fig.4.3. The zero lift angle has been found at -3o angle of attack. Then the lift co-
efficient increases linearly with the increase of angle of attack up to approximately 15o. In
other words, the lift co-efficient increases linearly with the increase of angle of attack up to
15o. As such the stalling angle is found at 15o. It is also observed that the CLmax for this models
approximately 1.05.
The variation of drag co efficient with angle of attack at 20 m/sec at different angle of attack
is shown in fig. The shape of the drag co-efficient vs angle of attack curve is found linear. As
such, the drag co-efficient increases with the increase in angle of attack. The value of drag co-
efficient at 15 angle of attack is found 0.2.
0.2
Fig 2.2 drag co-efficient with angle of attack
8.3 Comparison of angle of attack with lift co-efficient & drag co-efficient
The comparison graph for angle of attack, co-efficient of lift and co-efficient of drag for 20
m/s is shown in fig. From this graph we could observe that drag is less than the lift. Drag co-
efficient is found more due to increase of induced drag for trailing edge vortices from airfoil
shaped fuselage. It is because flow separation starts earlier.
1
co-efficient of lift & drag
0.8
0.6 Drag
0.4
Lift
0.2
0
-0.2 0 5 10 15 20
-0.4
Angle of attack
Fig 2.3 drag co-efficient and lift co-efficient with angle of attack
8.4. Lift to drag ratio curve
The lift to drag ratio curve of airfoil shaped fuselage with bi cambered wing UAV is shown in
fig.4.6 and it is found less for our model due to increase of induced drag for trailing edge
vortices from the airfoil shaped fuselage. But increased a significant amount of extra lift from
its wing due to bi camber shape.
0.35
0.3
0.25
Drag
0.2
0.15
-0.4 -0.2-0.05 0 0.2 0.4 0.6 0.8 1 1.2
Lift
9.0 Conclusions
An attempt has been made to study the design and flight characteristics of a simple
aircraft
Simple calculations of lift and drag are carried out considering the total weight of the
aircraft
The dimensions of the prototype was obtained from the standard procedures
The fabrication of the prototype was made using the simple light weight materials
The trial runs on propulsion and flight of the prototype was made
The complete design and flight of the prototype needs few more studies and controls
10.0. References:
I. Airplane design by Roskam [Tables & charts]
II. Aircraft Design by Raymer [Tables & charts]
III. Aircraft Performance and design by John. D. Anderson
IV. Aerodynamics, Aeronautics and Flight Mechanics by McCormick
V. Survey sheets
VI. Previous exercise results
VII. http://www.hq.nasa.gov/office/pao/History/SP-468/ch14-3.htm
VIII. http://www.aerospaceweb.org/question/airfoils/q0041.shtml
IX. Theory of Wing Sections by Abbott & Alber