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Aerospace Science and Technology 86 (2019) 215–235

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Aerospace Science and Technology


www.elsevier.com/locate/aescte

Aero-servo-elastic design of a morphing wing trailing edge system for


enhanced cruise performance
Maurizio Arena a,∗ , Antonio Concilio b , Rosario Pecora a
a
University of Naples “Federico II”, Department of Industrial Engineering (Aerospace Section), Via Claudio, 21-80125 Napoli (NA), Italy
b
CIRA – The Italian Aerospace Research Center, Via Maiorise-84081, Capua (CE), Italy

a r t i c l e i n f o a b s t r a c t

Article history: The Adaptive Trailing Edge Device (ATED) was a sub-project inside SARISTU (Smart Intelligent Aircraft
Received 18 March 2018 Structures, 2011–2015), an L2 level project of the 7th EU Framework programme coordinated by Airbus,
Received in revised form 26 September aimed at developing technologies for realizing a morphing wing for the improvement of general aircraft
2018
performance. That study, divided into design, manufacturing and testing phases, involved universities,
Accepted 7 January 2019
Available online 15 January 2019
research centers and leading industries of the European consortium. The aim of the present work
is to predict the aero-servo-elastic impact of a full-scale morphing wing trailing edge on a CS-25
Keywords: category aircraft. Within SARISTU, many FE models were realized, taking into account the complete
Adaptive trailing edge device and complex adaptive wing structure behavior. Those numerical representations referred to the 5.5 m
Aeroelastic stability wing section that was then employed for wind tunnel tests; such segment included the winglet and was
Airworthiness representative of the outer wing segment (namely, the so-called “aileron region”). Those models were
Failure taken as reference to develop numerical representation of the considered wing that better suited the
FEM morphing
complete wing segment, from the fuselage attachment to the end of the flap region. Therefore, a scaling
process was necessary, aimed at translating the former architectures to the new geometries. This kind of
extrapolation had the advantage to take into account larger rooms to host the complex actuator system
with all its components. MSC Nastran® FE models were elaborated to estimate stiffness and inertial
distributions that allowed constructing the stick-beam mock-up of the complete structure. Several cases
of flutter analysis were investigated by an in-house code, SANDY 3.0, to verify the safety requirements
imposed by the applicable aviation regulations (paragraph 25.629, parts a and b-1). Moreover, dynamic
stability assessment was performed with respect to single and combined failures of the actuation line
and kinematic chain enabling morphing in order to support FHA (Fault and Hazard Analysis).
© 2019 Elsevier Masson SAS. All rights reserved.

1. Introduction best geometrical layout matches the actual current situation, fitting
specific and mutating states. Chord and span-wise wing camber
1.1. Framework of the research variations may allow chasing somehow that optimal shape, target-
ing to maintain aerodynamic and structural performance at high
Looking at the current “greening” and “low-noise” research levels. Trailing Edge modification is an attractive and simple way
scenario, innovative solutions for more economical and ecologi- to achieve that goal. An Adaptive Trailing Edge Device (ATED) could
cal future aircraft are necessary in order to meet the challenging for instance allow reducing the operational fuel consumption by
requirements of the ACARE (Advisory Council for Aeronautics Re- pursuing the minimal drag effect or reducing the overall design
search in Europe) 2020 Agenda like reduced CO2 emissions and weight by continuously re-arranging the load distribution (alleviat-
noise levels by significant amounts. Civil aircraft flight profiles are ing the tension state at the wing root). Adaptive morphing trailing
almost standard but aircraft may fly fast or slow, at low or high edges offer the potential to improve the fuel efficiency of commer-
altitude depending on a number of factors. For large commercial cial transport aircraft, [1]. Such concepts were deeply faced within
vehicles, lift coefficient can range between hundredths and tenths SARISTU (Smart Aircraft Intelligent Structures), a large industrial
of units while aircraft weight reduces by a 30% as fuel burns. The project funded by the European Union (2011–2015) that dealt dif-
fusely with the development and implementation of adaptive wing
systems on-board of large commercial aircraft, [2]. In detail, three
* Corresponding author. different concepts were investigated [3]: an adaptive leading edge,
E-mail address: maurizio.arena@unina.it (M. Arena). for preserving the laminar flow quality and increasing the take-

https://doi.org/10.1016/j.ast.2019.01.020
1270-9638/© 2019 Elsevier Masson SAS. All rights reserved.
216 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

Nomenclature

A /C Aircraft FEM Finite Element Model


AIC Aerodynamic influence coefficients Fy Force acting along y-axis
AR Aspect Ratio GC Gravity Center
ATE Adaptive Trailing Edge GJ Torsional stiffness
ATED Adaptive Trailing Edge Device Ka Locked actuator (torsional) stiffness
BMx Bending moment about x-axis L Lift
BM z Bending moment about z-axis MAC Mean Aerodynamic Chord
conm2 Concentrated (lumped) mass element ([29]) MT Torque
D Drag rbe2 2 nodes rigid body element ([29])
DOF Degree Of Freedom RBM Root Bending Moment
DMIG Direct matrix input at grids ([29]) Ry Rotation around y-axis
EA Stiffness to normal force Rz Rotation around z-axis
EImax Maximum bending stiffness Ty Displacement along y-axis
EImin Minimum bending stiffness Tz Displacement along z-axis
F Frequency VD Dive speed
FE Finite Element λ = |T z / R y |

Fig. 1. SARISTU technology demonstrator @ TsAGI (Moscow, RUS) (a); test-set up schematic (b), [4].

off and landing performance; an adaptive winglet for alleviating power-supply, Fig. 1(b). Fig. 2 shows the ATE structural layout and
the gust effects and modulating the aerodynamic load shape along its location on the installed demonstrator. Regarding this point, it
the wing; an adaptive trailing edge, to face the aforementioned should be clarified that the selected region was used for practi-
objectives, [4]. All these systems were designed following the reg- cal reasons: that place is in fact reserved to the ailerons, while
ulations and prescriptions, proper of CS-25 aircraft, with the per- the flaps are located in the medium and inner part, towards the
spective of a real integration on-board of existing machines. This wing root. The attained results from the preliminary design of the
was one of the major challenges of the SARISTU project, forcing the adaptive trailing edge were therefore scaled to the available zone
choices towards widely commercial components while confining in order to manufacture and test the preliminary prototype. In this
the innovations to the global architecture and specific necessary context, a relevant attention was given to the release of refined
components like adaptive skins, able to withstand the operational drawings for the complete ATE demonstrator, spanning over the all
forces and exhibit extreme strains, up to several percentage units. wing, [2].
The higher system complexity with respect to conventional struc-
1.2. Literature review
tures, together with the increased degrees of freedom (naturally
related to the augmented deformability) led to the simple con-
Within the adaptive surfaces design processes, the aeroelastic
sideration of taking into account aeroelastic issues since the pre-
stability assessment have attracted increasingly considerable atten-
liminary design phase. Within the SARISTU program, the Adaptive tion by many research and industrial teams. Prof. Eli Livne began
Trailing Edge Device (ATED) was manufactured and was installed his paper in 2003 writing that the aeroelasticity was still dynamic,
on a full-scale wing section, 5.5 m span. Two other adaptive com- challenging, and a key part of cutting-edge airplane technology, [6].
ponents were also deployed on that wing section: an Adaptive This is true even today, especially in the ambitious scenario of re-
Winglet and an Adaptive Leading Edge, [3]. The complete adap- search that focuses on the design up to the actual implementation
tive wing did then undergo an extensive wind tunnel investigation of unconventional structures on the aircraft, [7,8]. Recently, several
at TsAGI facilities in Russia, Fig. 1(a), [5]. In that circumstance, studies have been addressed to investigate the aeroelastic behavior
the single devices behavior was tested, also including concurrent of span morphing wings. An interesting review of the progress per-
actions yet restrained to few cases. Tests were carried out on a full- formed in aerodynamic and aeroelastic analysis of flapping wings
scale technology platform, widely representative of the outermost was presented by W. Shyy, H. Aono and S.K. Chimakurthi in [9].
region of the reference wing (5.5 m span, including the winglet ex- A variable-shaped structure in view of the fact that is charac-
tension) and equipped with the cited adaptive systems and related terized by a higher flexibility, certainly requires a careful study
M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235 217

Fig. 2. Technology demonstrator and ATE demonstrator region.

of aeroelastic performance, even greater than traditional config-


urations. Several basic theoretical schemes were implemented in
literature to study the aeroelastic phenomena of adaptive struc-
tures. A time-domain based dynamic model has been developed
by R.M. Ajaj and M. Friswell to analyse the aeroelastic behavior of
compliant span morphing wings, [10]. A sensitivity study between
two potential span morphing concepts was carried out: Zigzag
Wingbox and the GNATSpar wing, [11,12]. The study described in
[13,14] addresses flutter instability for novel morphing wing at low
speed considering different morphing wing configurations for UAV.
H. Ren and Q. Zhiping proposed a first-order state-space aeroelastic
model to forecast transient aeroelastic responses and flutter char-
acteristics of a variable-span wing during the morphing process,
[15]. In [16], both experimental and numerical activities aimed
at flutter margin evaluation were discussed for a wing demon- Fig. 3. Wing main components.
strator with a morphing composite upper surface as possible and
fast implementation on an already existing structure. J. Murua,
and outer segments – i.e., before and after the typical kink). The
R. Palocios and J. Peiro explored the effects of chord-wise flexibil-
studies concern the complete system and its effect on the aeroe-
ity on the dynamic stability of compliant airfoils approaching with
lastic behavior of the considered wing. The research is then de-
classical two-dimensional aeroelastic model, suitably modified in
veloped to include safety issues, namely emphasizing the effects
order to capture time-varying camber deformations, [17]. Impor-
of failures, affecting some actuator system reference components
tant aerodynamic and aeroelastic investigations were performed in
or involving more devices. Aero-servo-elastic studies are therefore
[18], achieving some key results for wing design with conformal
mandatory to confirm the reliability of the selected architecture
control surfaces. A fundamental issue highlighted in [9] for fur-
as a potential candidate for a real flyable application. Engineering-
ther research is need to be developed bio-inspired mechanisms for
oriented approaches were properly implemented, simulating the
the flapping wing. These mechanisms should include joints and
effects induced by variations of trailing edge actuators’ stiffness
distributed actuation to enable flapping and morphing. Most im-
on the aeroelastic behavior of the wing, also in correspondence
portantly, these mechanisms should be capable of mitigating wind
gust. In the light of these outlooks, novel variable-shaped struc- of different dynamic characteristics of the trailing edge compo-
tures were investigated by the authors to enable the controlled nent [23]. Moreover, flutter analyses were carried by considering
modification of the trailing edge shape for large civil aircraft appli- the morphing trailing edge device integrated into the full-scale
cations, [19–22]. SARISTU wind tunnel demonstrator, in order to assure the safety
of wind tunnel tests. The finite element model used for static
1.3. Aim of the work analyses was condensed into a dynamically equivalent one charac-
terized by a reduced number of degrees of freedom [24]. Referring
Literature works focus on 2D airfoil or deal with limited in- to such a condensed structural model, the present paper deals
vestigations on complete wings, yet simple-shaped like rectangular with the prediction of the aeroelastic response of the complete
planforms. In the recent past, the authors of this paper carried out wing, equipped with the Adaptive Trailing Edge, fully extending
extensive studies on dynamic aeroelastic characterization, yet con- along the inner and outer flap regions. Stiffness and inertial dis-
fined to full-scale wing sections for wind tunnel tests. In the cur- tributions of the complete wing system were then reconstructed,
rent work, moving from the previous results, the investigations are taking properly into account the presence of the movable surfaces,
expanded to a complete wing, representative of a CS-25 class air- neglected within SARISTU. For the sake of clarity, the reference
craft. The bio-mechanical concept, which will be described within wing segment, different from the ATE, was considered as a clas-
the text, adopted to induce camber variations encompassed seg- sical elastic, non-adaptive structure. The 3D sketch is reported in
mented adaptive ribs consisting of finger-like segments covered by Fig. 3, where the area of interest is highlighted. The case study
a hyperelastic skin. In the specific, the aerodynamic structure is has been modeled using extra-modes method, in which the adap-
equipped with an adaptive trailing edge deployed along its en- tive surface is treated as substructure hosted on a basic system,
tire span, and deployed along the flap region (including both inner i.e. the aircraft, [25]. A stick-equivalent model of the reference
218 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

structure was then generated in SANDY 3.0, propertary and not in service. Once the wing was defined, the region of interest was
yet commercially distributed set of Fortran/Matlab routine, which selected as the segment between the rear spar and the wing tip.
has been adopted for the definition of the coupled aero-structural The most severe aerodynamic actions were identified and the rela-
model as well as for the solution of aeroelastic stability equations tive loads computed. The adaptive structural system was then sized
by means of theoretical modes association in frequency domain. to resist those loads, according to the guidance of the CS-25 reg-
Doublet Lattice Method was implemented for the evaluation of ulations: research activities were carried out to substantiate the
the unsteady aerodynamic coefficients: a suitable 2D paneling was feasibility of morphing concepts in compliance with the demand-
implemented for such a purpose. Linear splines were used to inter- ing safety requirements applicable to the next generation green re-
polate modal displacements along the centers of the aerodynamic gional aircraft. Two major differences however should be declared,
panels and generalized aerodynamic forces were evaluated with for the sake of truth: 1. the project was carried out with respect
reference to the airflow conditions expected during flight envelope. to the selected wing region (aileron zone) because of the neces-
Furthermore, sensitivity calculations were carried out to evaluate sity to bring the full-scale object in wind tunnel; 2. the project
the aero-servo-elastic stability of global system with respect to considered the system to be attached directly to the wing box in-
single and combined failures of the actuators enabling morphing. stead of being part of the flaps. The first choice led to a more
Numerical results showed that – in nominal working conditions complex problem indeed, because of the room limitation and the
– the ATED has no impact on aircraft aeroelastic stability. Fail- growing importance of the local loads with respect to the global
ure checks have been then performed in order to support FHA ones, by moving towards the wing extremity. Within SARISTU, the
(Fault and Hazard Analysis) specifications; catastrophic flutter in flaps were not considered part of the reference structure. In other
the flight envelope occurs only in the very remote event of mul- words, the original wing had only a fixed, non-movable trailing
tiple combined system failures (more than three actuators failure edge. There, the ATED would have been installed. This work hy-
and/or failure of more than three structural elements of the ATED). pothesis did not modify the adaptive system structural design: in
No catastrophic flutter occurs in case of single failure of any of the the end, a fixed part of the wing was considered instead than
ATED components. a flap segment. Of course, this choice simplified a lot the work
from the point of view of cabling deployment that should have
1.4. Reference system been taken into account if a working flap had been concerned
about, and the installation process, in general. A 5-bay morphing
Looking at Fig. 3, the global (aerodynamic) reference system demonstrator was finally realized (Fig. 4): this product is herein
(GRS) is defined as follows: considered as the reference architecture to extrapolate the prop-
erties of the adaptive trailing edge throughout the full-size wing
• Origin (O) at the intersection point between wing leading edge span, Fig. 3. The structural concept is mainly made of transver-
and A/C symmetry plane (π ); sal spars, which ensure the longitudinal stiffness of the different
• X axis passing through the intersection point (P) between A/C sections, and articulated ribs, which guarantee the chord-wise de-
symmetry plane and wing trailing edge line, oriented from O formability, Fig. 4.
to P;
• Y axis perpendicular to the A/C symmetry plane and oriented 2.2. ATED architecture
towards the RH wing tip;
• Z axis perpendicular to X Y plane and upwards oriented. The macroscopic result of the arrangement described in the
previous paragraph is a mechanical multi-box structure made of
2. The saristu “ATED” different blocks rotating along hinge lines parallel to the trailing
edge. The ribs are segmented along the chord and enable the cam-
2.1. ATED specifications ber variation of the airfoil through a properly designed finger-like
mechanism; the spars connecting the ribs segments ensure the ad-
The trailing edge movable part covers about 10% of MAC and is equate bending stiffness to withstand external loads and force the
constant along the span. In the investigated architecture, morphing ribs to morph in a conformal manner along the span (no twist
is enabled by a multi-finger system driven by load-bearing actua- is induced by rib camber morphing). The rib layout is detailed
tors. The realized schematic implements a synchronous mechanism in Fig. 5; such component is a single-DOF mechanism: in other
(2D-type) to provide camber variations but, within certain limits, it words, its geometry can change according to some pre-definite ra-
can be activated differentially (twist). Such a capability is expected tio of rotation among the different blocks. As it is shown in Fig. 5,
to be exploited in further realizations. The actuators may be driven the smart rib is made of four consecutive parts (B0, B1, B2 and B3)
in two different ways: through a classical feedforward scheme (di- connected to each other by three hinges (A, B and C), located along
rect input from the operator) or by the result of information gained the camber line. The first block, B0, is rigidly connected to the rear
by a widely distributed strain sensor network, filtered through a spar, while the other three elements can rotate around the connec-
devoted control system (a classical feedback scheme). In both the tion hinges simulating a finger-like schematic. The camber-line is
cases, however, the command is quasi-static: in fact, the aim of then reduced to a segmented chain. This 3-DOF may be reduced
the proposed system is to compensate the aircraft weight varia- to a 1-DOF system by introducing some additional constraints:
tions following the fuel consumption, by adjusting the shape of connection rod elements (steel links, L1 and L2) are hinged on
the aft part of the wing. An adaptive, highly deformable skin ab- non-adjacent blocks and force the camber line segments to rotate
sorbs part of the external loads and insures a smooth profile, [26]. according to specific gear ratios, [27].
One of the most relevant features of the referred system is the ca- The mechanism is driven by an actuation system that enables
pability to maintain its structural properties (i.e., the capability to morphed up and down configurations with a target deflection
bear loads, both internal and external) while being actuated. This range of 10 (±5) degrees. The command chain consists of an alu-
property translates in two main abilities: shape adaptation under minum linear guide architecture made of a rail, a gliding element
the action of the operational forces; attained shape keeping under and a carriage, and a steel leverage, made of a crank and a con-
the action of same forces. Such concepts drove the design of the necting plate, Fig. 6.
target Adaptive Trailing Edge. The choice of the consortium was The system activation causes the trailing edge geometry to
to size this system by the actual loads, acting on a real aircraft change according to the prescribed shape, Fig. 7. In any configu-
M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235 219

Fig. 4. Primary Structure of 5-bay demonstrator, hidden skin.

Fig. 5. Morphing rib architecture.

Fig. 6. Doubly servo-actuated rib: redundancy design.

ration, even during the motion, the multi-box structure is able to it was necessary to investigate how much the internal pressure
resist the static action of the external loads up to their extreme could cause significant deformation (bubbles) that could in turn
values, which guided its sizing as widely discussed in [28]. The affect the aerodynamic performance. Those studies confirmed that
adaptive skin is made of different parts, namely aluminum parts, such kind of effects could be neglected, [26] (see Fig. 8).
deployed on the different structural blocks, and foam elements, Reliable elementary methods combined with rational design
positioned at the hinge regions. Metal parts are used for preserv- criteria and advanced FE analyses were adopted to assess the ar-
ing the specified shape, while the soft elements absorb the large chitectural concept and the embedded actuation mechanisms. The
deformation that the system is required to suffer (in the specific present study refers to quasi-static devices, or systems that are
application, experienced strain is expected to be in the range up envisaged to deploy very slowly with respect to the dynamic char-
to 5%, i.e. 50.000 microstrain). The foam is free to move axially in acteristic of the whole aircraft structure. In this sense, the working
the hinge region and is constrained at the metal parts. Therefore, mechanism is not believed to modify the overall structural dy-
it can be said to be supported on the hinges. A further foam, pro- namic response. However, because different masses, stiffness con-
tective layer, runs all over the adaptive skin to preserve it from the tributions, geometry, and, above all, added degrees of freedom are
external environment at some extent. Because of this architecture, inserted within the original structure, dynamic structural response
220 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

Fig. 7. ATED configurations: morphed up (left) and down (right).

Fig. 8. ATED compliant skin solution [26,27].

may be critically affected by this new configuration. In particular, simulated via cbar/cbeam elements, pins allowed for the relative
aeroelastic effects may be crucial for the architecture safety. That rotation with the connected rib block. The FE model of the actu-
is the core analysis of the paper herein presented. ation system (mainly meshed with solid elements chexa) included
all the components of the aluminum linear guide and of the steel
2.3. ATED finite element model actuation leverage systems, Fig. 10. The actuator shaft was fixed to
the crank through the connecting plate, and was modeled with
A FE model was generated within SARISTU project mainly to ad- beam elements. The actuator was simulated with an equivalent
dress linear and non-linear static analyses of the morphing trailing lumped mass located in correspondence of its centre or gravity,
edge at limit and ultimate load conditions [28]. Modeling speci- Fig. 10(a). The referred arrangement considered the actuation sys-
fications were compatible with FEM customary approaches; mesh tem as it was “frozen” in a certain configuration, Fig. 10(b). In such
size and general properties were rationally defined in order to get
a way, the motor box did not contribute to the global stiffness of
detailed and reliable distributions of stress and strains especially
the system, while the articulation was simulated at its max rigidity
around holes while optimizing the computational time required
(clamped beam). This last assumption was judged as conservative
for each analysis. The model included the primary structure (mor-
during the stress analysis process, because it leads to the high-
phable and un-morphable boxes), the actuation system and the
est value of the stresses. The former hypothesis instead, assumes
skin panels and was generated in order to run in MSC-Nastran®
that the motor box is placed in a dedicated hollow, without con-
environment [29]. The adaptive skin consisted of a three level
curring to the load bearing property of the architecture; in this
structure: an aluminum sheet, connected to the rib and modeled
sense, it is also a conservative supposition. The final global finite
with cquad4 elements a hyperelastic sheet covering the external
system surface and modeled again with cquad4; foam strips, ap- element model consisted of a large number of nodes and elements,
plied along the span-wise direction at the hinges region, i.e. the necessary to properly represent the trailing edge structural sys-
region of max deformability, guaranteeing the morphing capability tem in its completeness. Apart of the actuation system and the
to the skin and modeled with solid elements, chexa type (Fig. 9). block-connection links, made of steel, and the “composite” skin,
All the fasteners among the skin layers and spars (also meshed the other elements are made of aluminum (Al2024-T3). The mate-
with cquad elements) were simulated by means of cbush con- rials properties are listed in Table 1.
nections thus accurately accounting for the transmission of forces Global and local stress analyses were performed under the ac-
between the morphing skin and the main structure of the demon- tions of distributed pressure fields on the upper and lower skin
strator [30]. The internal hinges (spherical and cylindrical) were panels. The survey of any buckling or vibration instability was per-
modeled with a usual scheme of rigid body connections based formed by dedicated linear-nonlinear and dynamic simulations. In
on rbe2 elements: an independent node was placed at the ideal order to be more conservative, no inertial alleviation was taken in
centre of rotation while all the nodes along the hole’s surface host- account during the simulations. Non-linear static analysis was then
ing the hinge were slaved to it. At the end-nodes of the shafts, addressed to evaluate deformation and stress up to ultimate load
M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235 221

Fig. 9. FEM details: skin–rib interface (up), spars (low, left) and morphing rib (low, right).

Fig. 10. FEM actuation details.

Table 1 ness sake, a general description of SANDY 3.0 software [23,36,37]


Morphing system materials. has been provided at the appendix of this paper.
Material E (GPa) ρ (kg/m3 ) ν Items
Steel 17-4 PH 210 7800 0.3 Actuation system 3.1. ATED equivalent structural model: evaluation of stiffness and
components; Rib block inertial properties
links
Al 2024-T3 70 2780 0.33 Ribs; Spars
In order to perform fast sensitivity aeroelastic analyses, a sim-
Hyperelastic layer 0.0017 10 0.33 Skin
Foam 0.0037 10 0.33 Skin plified structural model of the trailing edge system was generated
referring to a stick-equivalent representation [25]. Relevant stiff-
ness and inertial properties were extracted from the refined FE
model adopted for static stress analyses and roughly described in
condition, defined as limit loads multiplied by the reserve factor of
Section 2.3 [23,27].
1.5. The absence of any structural instability up to limit load con-
Block 0 characteristics were evaluated with respect to its elastic
dition was then proven by means of linear buckling analysis [27,
axis, y, which was evaluated by means of an iterative procedure
28].
characterized by seven main steps [37,38]:

3. Aeroelastic model generation 1. A trial position of the elastic axis was at first assumed; the FE
model of Section 2.3 was modified by adding support nodes
A stick-equivalent model of the reference structure was then in correspondence of the intersection between the elastic axis
generated in SANDY 3.0, an in-house developed code, that was and the rib planes;
used for the definition of the coupled aero-structural model as well 2. At each rib station, rbe2 elements were added to the model to
as for the solution of aeroelastic stability equations by means of slave all the rib boundary nodes to the support node defined
theoretical modes association in frequency domain. For complete- at previous step;
222 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

Fig. 11. Detail of FE Block 0 model. (For interpretation of the colors in the figure(s), the reader is referred to the web version of this article.)

3. The first support node along the span was constrained in all – z-axis normal to xy plane and upwards oriented.
6 dofs while an unitary torque moment, M T , was applied in • y is the generic coordinate along the y-axis.
correspondence of the last support node along the span; • GJ( y ) is the torsional stiffness distribution.
4. Static analysis was performed in MSC-Nastran® and the fol- • EImin ( y ) is the vertical bending stiffness distribution (stiffness
lowing displacements were evaluated: to bending across xy plane).
T zi : displacement of the master (support) node of the i-th rib • EImax ( y ) is the lateral (fore and aft) bending stiffness distribu-
along the axis z (vertical displacement, induced by M T ); tion (stiffness to bending across yz-plane).
R yi : rotation of the master node on the i-th rib along elastic • EA( y ) is the distribution of the normal stiffness, exhibited with
axis y (torsion induced by M T ); respect to forces acting along the elastic axis.
5. Ratios λi = | T zi / R yi | were evaluated at each rib location thus • M T and R y ( y ) are respectively an arbitrary torque moment
providing the mean offset of the actual elastic line with re- acting around the elastic axis ( y-axis) at its free-end and the
spect to its supposed position; rotation induced by M T around the y-axis of the cross section
6. At each rib location, the master node defined at step 1 was at the co-ordinate y.
shifted chord-wise by the amount λi ; • BM X and R x ( y ) are respectively an arbitrary bending moment
7. Steps from 3 to 6 were iterated until all ratios λi resulted prac- acting around the x-axis at the elastic axis free-end and the
tically negligible. rotation induced by BM x around the x-axis of the cross section
at the coordinate y.
The elastic axis obtained for of Block 0 is represented in Fig. 11 by • BM z and R z ( y ) are respectively an arbitrary bending moment
a dashed line. acting around the z-axis at the elastic axis free-end and the
Once the B0 elastic axis was determined, stiffness distributions rotation induced by BM z around the z-axis of the cross section
were determined through the classical equations of the De Saint- at the coordinate y.
Venant’s theory:
• F y and T y ( y ) are respectively an arbitrary force acting along
the elastic axis ( y-axis) at its free-end and the displacement
MT induced by F x along the y-axis of the cross section at the co-
GJ( y ) = (1) ordinate y.
d
dy
[ R y ( y )]
BM x R y ( y ), R x ( y ), R z ( y ) and T y ( y ) were evaluated by means of lin-
EImin ( y ) = (2)
d
[ R x ( y )] ear static analysis performed in MSC-Nastran® . As usual for slen-
dy
der bodies, the shear stiffness was not taken in account; for high
BM z aspect ratio wings (AR > 10) the aeroelastic effects due to shear-
EImax ( y ) = (3)
d
dy
[ R z ( y )] induced displacements are indeed negligible with respect to those
due to bending- and torsion-induced displacements [25].
Fy The stiffness distributions evaluated along the ATED demonstra-
EA( y ) = (4)
d
dy
[ T y ( y )] tor span were then extrapolated along the outboard region of the
wing, assuming a polynomial interpolation of the characteristic pa-
where: rameters like GJ (torsional stiffness), EI (bending stiffness) and EA
(axial stiffness), Figs. 12–15.
• x, y , z are the axes of the Cartesian reference system charac- The inertial properties, namely masses and moments of iner-
terized by: tia, were then compute referring to properly sliced portions (bays)
– origin at the root of the B0 elastic axis (at the inner rib of the FEM described in Section 2.3. Because the movable part
location of the item); of the ATE, including the blocks B1, B2 and B3, is not tapered,
– y-axis coincident with the item elastic axis and positively an extension of the 5-bay model was considered along the outer
oriented towards the item tip; wing region without altering the ATED chord. On the other hand,
– xy-plane for the elastic axis, normal to the B0 plane and for what regards the block B0, the extension along the span was
parallel to the plane, tangent to the B0 mean line; done while considering its chord as homothetically variable along
M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235 223

Fig. 12. Torsional stiffness, Block 0.

Fig. 13. Vertical bending stiffness, Block 0.

Fig. 14. Fore & Aft bending stiffness, Block 0.

Fig. 15. Axial stiffness, Block 0.


224 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

Table 2
Mass properties.

ID block Demonstrator mass (kg) Outboard region mass (kg)


B0 16.30 128.50
B1 4.80 13.50
B2 4.00 11.20
B3 6.10 17.10

Global mass (kg) 31.20 170.30

the wing-box and the trailing edge, respectively. At the occur-


rence, trailing edge mass was split in two separate contributions,
for the fixed and the movable parts. After having computed the
mass properties by the FE data, these numbers were assigned
to conm2 elements located at the centres of gravity of the bay
components, Fig. 18(b). The evaluation of the wing-box (/winglet
box) elastic axes and of the spanwise stiffness distributions was
carried out by following the same procedure illustrated in Sec-
tion 3.1 [23]. As usual for kinked wings, the elastic line was ap-
proximated with a straight axis, Fig. 18; the deviation between
Fig. 16. Block 0 design extrapolation.
the elastic line and the assumed straight axis showed however
a good correlation index, R 2 = 0.7611, just after few iterations,
Fig. 19.

3.3. Generation of the stick-beam model

The set of inertial and stiffness properties evaluated in the pre-


vious paragraph were used to properly define equivalent beam
models representing the right wing, winglet and the adaptive trail-
ing edge. The equivalent beam models were generated in SANDY
3.0 environment and properly linked to each other in order to
adequately represent the stiffness of the components joints. The
obtained equivalent beam representation is depicted in Fig. 20.
Fig. 17. Mass condensation at gravity center.
In the schematic representation, the concentrated masses were
associated to the closest grid of the attained model. The left
the span, Fig. 16. For each block portion, the lumped masses/in- half of the model was obtained by a simple mirroring process;
ertias were considered to be applied to the gravity centre of each right and left wings elastic axis were linked to a central node,
block, via conm2 elements, Fig. 17. The total masses of each block, via DMIG elements, [29], simulating the stiffness of the wing-
for the demonstrator and the outboard region, are listed in Ta- fuselage interface. Another DMIG element was used also to connect
ble 2. the winglet and the wing-box elastic axes The lumped mass and
the plunge inertia of the aircraft body, was simulated by a fur-
3.2. Wing equivalent structural model: evaluation of stiffness and ther conm2 element, placed on the abovementioned central node.
inertial properties The end-points of the morphing trailing edge hinge lines were
then linked to the elastic axis of the wing by 2-node elastic el-
Stiffness and inertial properties of the equivalent beam, rep- ements (cbeam). Pin flags were imposed at the end-nodes to per-
resentative of the wing-box and winglet, were determined with mit rotations around the hinge lines. A torsional spring simulated
reference to a global FE model, developed by project’s partners the presence of the actuator system at the B1 hinge axis, while
to address the elastic behavior of the reference wing where the 2-nodes DMIG elements involving rotational degrees of freedom
ATED had to be installed on, Fig. 18(a). Three lumped mass prop- only ([ K ]456 ) were used to represent the connections B1–B2 and
erties were evaluated for each bay, associated to the leading edge, B2–B3, Fig. 21.

Fig. 18. Wing and winglet reduced models.


M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235 225

Fig. 21. Zoom on root station of left ATED, items assembling.

Fig. 19. Elastic axis determination, wing-box.


pled structural/aerodynamic model adopted for aeroelastic stability
analyses has been depicted.

4. Flutter analysis

Having set the aeroelastic model, and disposing of a reliable


tool for the related analysis, several cases of flutter investigations
were performed in order to verify the safety requirements, im-
posed by the applicable aviation regulations in specific operation
conditions, [42]:

• System fully operative;


• System in failure condition.
Fig. 20. Equivalent structural model of the wing.
4.1. Assumptions and investigation cases
3.4. Aerodynamic model and modes interpolation
Flutter analyses were carried out in SANDY 3.0 environment un-
The aerodynamic model, Fig. 22, was implemented in SANDY der the following assumptions:
3.0 with reference to the standard mesh criteria and procedures
usually recommended for the application of the doublet lattice • PK-continuation method, [25], with rationalization of general-
method (DLM), [31–35]. The middle plane of the wing was meshed ized aerodynamic forces, [43,44], for the evaluation of modal
into 8 macro-panels for the left and wing side, respectively. These frequencies and damping trends versus flight speed;
macro-panels were further meshed into elementary boxes, whose • Theoretical elastic modes association in the frequency range
density was higher for the movable trailing edge to better esti- 0–50 Hz (elastic modes being pertinent to free-free aircraft,
mate the generalized aerodynamic forces due to its motion [36]. with only plunge and roll motions allowed as depicted in
Modal displacements at the center of each aerodynamic box were Fig. 24);
obtained by means of linear and surface spline functions, attached • Modal viscous damping (conservatively) equal to 0.01 for all
to support-nodes of the structural model; in Fig. 23. The cou- the elastic modes;

Fig. 22. Aerodynamic model (thick lines represent panels’ boundaries).


226 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

Fig. 23. Aeroelastic model.

Fig. 24. A/C rigid modes analysis.

• Sea-level altitude, for the considered aircraft, flight speed 


15
1 ∼ 1
range set at 0–250 m/s (≈1.15 V D 1 ); = (7)
Ki KG
• Flight speed range set at 0–V D in case of actuators malfunc- i =1

tion and other system failures. By placing:

The harmonic frequency of the trailing edge was set by ma- Ki = K , ∀i (i = 1 : 15) (8)
nipulating the stiffness of the torsional spring, used to simulate it was possible to build the geared elasto-kinematic matrix.
the adaptive trailing edge actuators. In order to get a given fre- The blocks 2 and 3 follow the B1 rotation according to specific
quency f , the torsional stiffness K a of the actuators, was imposed kinematic gear ratios [13]. A sketch of those connections is shown
equal to: in Fig. 25, where:

K a = (2π f )2 · I (5) • β is the block B i rotation;


• δ R is the rigid rotation of B i +1 with respect to B i ;
where I stands for the inertia of the complete ATE around its • N = δ R /β is the geared ratio of B i +1 with respect to B i ;
hinge line. The experimental frequency of the so-called “morphing • δe is the elastic rotation of B i +1 with respect to B i ;
mode” frequency resulted around 30 Hz. The generalized stiffness
The total rotation δ of B i +1 with respect to x-axis is therefore
was then:
equal to:

K G = (2π · 30)2 · 0.6123 = 22075.147 N/m (6) δ = β + δ R + δe (9)

The virtual adaptive trailing edge consists of 15 servo-actuated The deformation energy of the spring K is:
ribs. Each actuator was simulated by a torsional rigid spring: such 1
local stiffness (i.e. the stiffness of the single block) was given by u= K δe2 (10)
2
considering the layout series of the connections:
being for (9):

δe = δ − β − δ R = δ − β − N β = δ − β(1 + N ) (11)
1
V D indicates the dive speed of the aircraft. The exact value of the dive speed
has been omitted for confidentiality reasons. the (10) gives:
M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235 227

Fig. 25. Conceptual scheme of the elastic geared connection.

Fig. 27. Outer trailing edge symmetric harmonic, f = 5.89 Hz.

    
∂u
(1 + N )2 −(1 + N ) β
Fig. 26. Outer left trailing edge fundamental mode, f = 0 Hz.
∂β =K (13)
∂u
∂δ
−(1 + N ) 1 δ

1  2 This matrix has been determined according to design approach of


u= K δ − β(1 + N )
2 spring-tabs applied to elevator controls of large airplanes, largely
1 1 discussed by H.W. Phillips in [45]. Adjacent blocks have geared ro-
= K δ 2 − K δβ(1 + N ) + K β 2 (1 + N )2 (12) tations due to the single-degree-of-freedom system layout. There-
2 2
fore, connections between the stick beam models of each block
and the stiffness matrix of the elastic geared connection is finally were made by DMIG elements built according to the geared elasto-
obtained, as: kinematic matrix description.

Fig. 28. Outer trailing edge antisymmetric harmonic, f = 5.91 Hz.


228 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

Fig. 29. V–g plots, [0; 50 Hz], [0; 250 m/s].

4.2. Preliminary verifications of the numerical model of trailing edge is identified: this ratio grows from Block 1 to
Block 3.
To simulate the actuator failure, it was assumed that the “mor- Relying upon a good representation of the condensed structure
phing mode” frequency should be equal to 0 Hz: in such a case, as well as the kinematic chain, other fast calculations have been
in fact, the first adaptive trailing edge harmonic should coincide addressed to outline the reliability of the simplified way to repli-
with a rigid rotation around its hinge line. Fig. 26 represents the cate the actuator. Referring to Equation (5), a torsional stiffness
outer left trailing edge symmetric harmonic assuming to release
value corresponding to a frequency of about 6 Hz, was performed
the Block 1 from the fixed system, showing also a zoom on the
to get a more accurate view of the morphing mode shape, which
trailing edge mode shape. For the sake of brevity, the equivalent
result relating to the right side is not reported. Such prelimi- would not be well captured instead at its real frequency of about
nary analysis made it possible to verify the quality of the nu- 30 Hz, because of a greater modal density. In Figs. 27 and 28, the
merical model in line with the design requirements. In this case, outer trailing edge symmetric and antisymmetric harmonic modes
a rigid mode that evolves according to the design geared ratio are respectively shown.
M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235 229

Fig. 29. (continued)

4.3. Trade-off – flutter analysis The analyses were aimed at estimating the minimum condition
of instability (catastrophic condition) for the entire aircraft. Behav-
The robustness of the system was then assessed with reference ior prediction in failure cases was performed, according to FHA
also to combined failure conditions. Even if not prescribed by air- (Fault and Hazard Analysis) standard industrial specifications, [46,
worthiness regulations, multiple failures were anyway investigated 47]. ATED functions have been qualitatively examined to identify
due to the deeply unconventional arrangement of the control sur- potential risks resulting from operational malfunction. The severity
face. Flutter cases analyzed are summarized below: of these hazards was determined and placed in specific classes, in-
dicative of the maximum tolerable probability of occurrence, [48].
(a) Baseline: fully operative system; In Fig. 29, the trends of modes frequencies and damping versus
(b) Links failure at a single station; flight speed (V–g plot) have been reported with reference to the
(c) Actuator group failure at a single station; mentioned conditions. The system exhibited a good robustness
(d) Actuator group and links failure at a single station; margin: actually, even in the case of combined failures, it proved to
(e) Actuator group and links failure at two stations; be stable, Fig. 29(d)–(e). The actuator and links failures were simu-
(f) Actuator group and links failure at three stations. lated by imposing a null torsional stiffness (K a = 0) and removing
230 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

Fig. 29. (continued)

the adjunct DMIG condensation matrix. The stability diagram re- ing a bending-torsion response (Fig. 31). Flutter dynamics resulted
ferred to the case of a failure investing the actuator chain and the indeed more complex: also mode 5 is partially involved in the in-
links at first three stations of left ATED is reported in Fig. 29(f). stability.
In this case, flutter reveals at a speed equal to about 130 m/s.
The unconventional modes related to the multi-box structural ar- 5. Conclusions
rangement as well as to local failure of actuation systems, show
a relevant participation level in critical coupling mechanisms in- The adaptive structures concept is of great interest in the aero-
volving lower frequencies modes such as wing bending (mode 1). nautical field because of several benefits, which can lead to. Im-
An accurate analysis of the cross modal participation factors into provements in terms of aerodynamic efficiency and manoeuvra-
flutter mode was then performed in order to isolate the principal bility were proved by many international studies. In the modern
eigenvectors that were involved in the detected dynamic instabil- ambitious research scenario, the aeroelastic study is acquiring a
ity, [49,50], Fig. 30. It came out that the detected phenomenon dominant aspect in the design phase, being the structural com-
was mainly related to the coupling of two modes (binary flutter). plexity of morphing systems much more complex. The develop-
They were the normal shapes number 12 and number 14, induc- ment of novel structural architectures, implementing and integrat-
M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235 231

the large deformation induced by ribs kinematics while providing


enough stiffness to properly withstand external aerodynamic loads.
Starting from a FE model of the ATE demonstrator, its structural
properties have been rationally extended to the virtual outboard
region of a large aircraft. Dynamic condensation led to a reduced
model with fewer degrees of freedom, based on the generation of
stick-beam equivalent scheme and DMIG matrices. The condensed
dynamic model of flapped region was then assembled to the stick
one, representative of the CS-25 wing. Several numerical compu-
tations were performed in compliance with CS-25 airworthiness
requirements in order to verify the absence of the flutter criti-
calities up to 1.15V D in nominal conditions and V D in case of
a single failure. Obtained results showed that ATED is not respon-
sible for any flutter instability as regards the directional analysis.
Fig. 30. Flutter dynamic, modal cross-participation factor.
Moreover, failure checks were performed to support FHA specifica-
tions; a catastrophic event verifies only in case of three consecu-
ing innovative materials and actuation systems is mandatory for tive stations failure. The next target will be to predict the aeroe-
succeeding in these critical tasks. Conventional high lift systems, lastic behavior of the system in the case of actuators jamming.
such as flaps or slats, are the common way to modify aircraft Both single and multiple jamming cases could be resulted prac-
wing geometry during take-off and landing in order to provide ad- tically not so critical from the aeroelastic standpoint: the increase
ditional lift at low speed. However, they have limited efficiency in generalized stiffness, in fact, could cause the rise in frequency
due to the geometric discontinuities, require high installation ef- of unconventional elastic modes, which could be also out of the
forts and offer no functional flexibility in cruise, as, for instance, spectral range of interest for flutter investigation. Instead, the ex-
differential surface deflection. A novel architecture enabling wing pectation is to face a pure static problem: the stiffness increase
trailing edge camber morphing was addressed with reference to can modify the load distribution and cause the failure of some
large aircraft applications (EASA CS-25 category). The conventional actuation systems in turn leading to unstable coupling mecha-
monolithic box arrangement was replaced by a multi-box solu- nisms involving lower frequencies modes as the wing bending and
tion characterized by conventional spars and segmented adaptive other low-generalized mass secondary modes. Anyway, the results
ribs. Single-degree-of-freedom mechanisms, driven by load-bearing achieved allow for highlighting in this preliminary design stage,
electro-mechanical actuators, were implemented to change the a high level of robustness of the innovative synchronous system.
wing trailing edge shape by controlling the adaptive ribs indi- These outcomes could extremely encourage and provide motiva-
vidually. A compliant multi-layer skin was used to accommodate tions for further investigations of twist morphing technology for

Fig. 31. Main mode shapes.


232 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

Fig. 31. (continued)


M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235 233

Fig. 31. (continued)

high-aspect-ratio wings, implementing additional active load con- • Aerodynamic module;


trol functionalities. • Aeroelastic module.

Conflict of interest statement The dynamic module includes a generator of A/C structural and in-
ertial models and an internal FE solver for the evaluation of A/C
The authors declare no conflict of interest. modal parameters. In order to perform reliable modeling in rea-
sonable time, only two typologies of elements are available:
Acknowledgements
• Simple one-dimensional elements (beam, rod, rigid-link,
Part of the research herein reported has moved from re- spring);
sults achieved within the European Union Seventh Framework • DMIG (Direct Matrix Input at Grids) elements for a correct
Programme (FP7/2007–2013) under Grant Agreement n◦ 284562 evaluation of stiffness and inertial properties of those parts re-
(SARISTU). The authors would like to thank all the partners in- quiring a more sophisticated representation.
volved in the design of the morphing trailing edge device (ATED),
this paper inspires to. DMIG elements may be imported from commercial FE softwares
(e.g., MSC-NASTRAN® [15]); the same applies to A/C modal param-
Appendix A. SANDY Software v3.0: general description eters (mode shapes, frequencies, generalized masses, and damping)
that, moreover, may be imported from GVT experimental data. In
SANDY 3.0 is a proprietary non-commercial code which has addition to the A/C structure normal modes, the dynamic module
been developed and upgraded by M. Pecora and R. Pecora within allows for including extra-modes correlated to the movable sur-
the last twenty-five years with the intent of providing an excel- faces, in order to simulate loads alleviation systems, based on the
lent and reliable tool for static and dynamic aeroelastic and aero- use of those devices in feed-back with A/C kinematic parameters
servo-elastic analysis of aircraft. Rational approaches and validated (acceleration, velocity, displacement), and/or perform fast instabil-
numerical methods, compliant with the CS-25 and CS-23 EASA ity analyses in presence of powered or fly-by-wire controls.
standards, have been implemented in a multidisciplinary compu- The aerodynamic module is characterized by a generator of
tational environment, able to accomplish the following main tasks: aerodynamic models, coupled to an internal solver for the eval-
uation of modal pressure distributions by means of consolidated
• Generation of A/C dynamic model (structural and inertial mod- numerical methods, like the Doublet Lattice Method (DLM). More
els); in detail, the module provides the capability of generating three-
• Generation of A/C aerodynamic model; dimensional compressible aerodynamic models, and the possibility
• Generation of accurate transfer matrices, interfacing between of performing local corrections in the pressure distributions to take
dynamic and aerodynamic models; into account the effects of the movable surfaces aerodynamics (as
• Evaluation of A/C static and dynamic acceleration and loads recommended by FAA AC 25.629-1A paragraph 6).
response due to flight and ground manoeuvres and/or gust; The aeroelastic module is constituted of routines for:
• Evaluation of A/C static and dynamic acceleration and loads
response to movable lifting surfaces deflections imposed by • Interpolating modal displacements on the aerodynamic lattice
mechanical and/or electro-mechanical control circuits; (matching routines implementing 3D-spline methodologies);
• Evaluation of divergence, control reversal and flutter speeds. • Evaluating generalized aerodynamic pressures/forces and
steady/unsteady aerodynamic influence coefficients;
The computational tools and the numerical methods therein im- • Solving the aeroelastic equations describing the A/C response
plemented, assure fast analyses aimed also at investigating the in- and the instabilities identification.
fluence of several design parameters on the A/C aeroelastic behav-
ior. In other terms, the code permits a fast sensitivity aeroelastic The developed tool allows for managing multi-parametric anal-
analysis with respect to variations of some A/C components struc- ysis in a more fluent way compared to commercial standards,
tural and dynamic properties, including also the integrated control thus leading to relevant computational time savings. Engineering-
circuits. The highly efficient computational structure is based on oriented results can be achieved by solving the classic aeroelas-
intercommunicating routines, running in a common software en- tic equations respect to the speed (dynamic pressure) in order
vironment (Visual Fortran/Matlab) and properly organized in three to find the best combination between crucial design parameters
macro-modules: like for example balancing ratio or control line stiffness. Soft-
ware performance has been actually positively tested during the
• Dynamic module; aeroelastic certification process of a wide set of commercial air-
234 M. Arena et al. / Aerospace Science and Technology 86 (2019) 215–235

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