Design and manufacture of propellers for small unmanned aerial vehicles

2016 ◽  
Vol 4 (4) ◽  
pp. 228-245 ◽  
Author(s):  
Brian Rutkay ◽  
Jeremy Laliberté
Keyword(s):  
Additive Manufacturing ◽  
Wind Tunnel ◽  
Unmanned Aerial Vehicles ◽  
Wind Tunnel Testing ◽  
Performance Requirements ◽  
Propeller Design ◽  
Aerial Vehicles ◽  
Aircraft Performance ◽  
Design And Manufacture ◽  
Propeller Performance

The objective of this research was to develop a process for the design and manufacture of mission- and aircraft-specific propellers for small unmanned aerial vehicles. This objective was met by creating a computer program to design a propeller that meets user-defined aircraft performance requirements within the limitations of the electric motor, user-selected materials, and manufacturing methods. A comprehensive review of prior UAV propeller design and additive manufacturing for small propellers is also presented in this paper. The use of additive manufacturing (3D printing) in making flightworthy propellers was explored through material testing, manufacturing trials, and by testing the propellers under simulated flight conditions in a wind tunnel. It was found that the propeller performance generated nearly the predicted design thrust but the efficiency and power consumption could not be accurately measured with the present test setup. While flight testing was not completed at this time, ground and wind tunnel testing were sufficient to demonstrate the feasibility of producing flightworthy propellers using additive manufacturing.

Functional Prototyping and Tooling of FDM Additive Manufactured Parts

2014 ◽  
Author(s):  
Farzad Rayegani ◽  
Godfrey C. Onwubolu ◽  
Attila Nagy ◽  
Hargurdeep Singh
Keyword(s):  
Fluid Dynamics ◽  
Additive Manufacturing ◽  
Wind Tunnel ◽  
Wind Tunnel Testing ◽  
Tool Paths ◽  
Aerodynamic Properties ◽  
Vacuum Forming ◽  
Computational Fluid Dynamics Cfd ◽  
Functional Prototype ◽  
Tunnel Testing

In this paper, we present two additive manufacturing applications: (1) vacuum forming tooling using AM; (2) rocket functional prototype using AM for computational fluid dynamics (CFD) and wind-tunnel testing. The first application shows how additive manufacturing (AM) facilitates the manufacture of vacuum formed parts, which allows such parts to be easily produced especially in the manufacturing sector. We show how combining the advantages of the CAD and FDM technology, vacuum forming can be completed quickly, efficiently and cost effectively. The paper shows that using modified build parameters, the tools FDM creates can be inherently porous, which eliminates the time needed for drilling vent holes that are necessary for other vacuum forming tools, while improving part quality with an evenly distributed vacuum draw. Using SolidWorks CAD software, the model of the tool is created. The STL file is exported to the Insight software, and we present how the Tool Paths Custom Group feature is applied to optimize the tool-paths file and then sent to the FDM system that prints the tooling from ABS engineering thermoplastic. The tooling is then used in the Formech 686 manual vacuum forming machine to produce the vacuum formed part. The second application shows how additive manufacturing (AM) has been applied to producing functional model for wind–tunnel testing, as well as providing computational fluid dynamics (CFD) tool for comparing results obtained from the wind-tunnel testing. The present work is focused on applications of FDM technology for manufacturing wind tunnel test models. The CAD model of a rocket was analyzed for its aerodynamic properties and its functional prototype produced using AM for use in wind–tunnel testing so as to verify and tune the aerodynamic properties. Initial wall conditions were defined for the rocket in terms of the air velocity. The flow simulation was carried out and the goals examined are the velocity and pressure fields around the rocket model. The paper examines some practical issues that arise between how the model geometry for CDF process differs from that that of the FDM process. Consequently, we show that AM-based fused deposition modeling (FDM) technology is faster, less expensive and more efficient than traditional manufacturing processes for vacuum forming and for rapid prototyping of function models for wind-tunnel applications.

scholarly journals Optimization of SUAV’s propeller in a hover

2020 ◽  
Vol 313 ◽  
pp. 00045 ◽  
Author(s):  
Jakub Hnidka ◽  
Dalibor Rozehnal ◽  
Karel Maňas
Keyword(s):  
Unmanned Aerial Vehicles ◽  
Propulsion System ◽  
Simple Method ◽  
Widespread Application ◽  
Method Of Calculation ◽  
Propeller Design ◽  
Aerial Vehicles ◽  
Simplified Method ◽  
System Components ◽  
Overall Efficiency

Small unmanned aerial vehicles (SUAVs) have found a widespread application in past decades. However, as the criticality of the missions for which they can be used increases, the demand for improvement of their efficiency increases as well. The paper focuses on a propeller driven SUAVs of a multirotor type, equipped with an electric motor, battery and propeller. The paper presents a simplified method of calculation of the SUAV maximal endurance, if the characteristics of all components of the propulsion system are known. To improve the overall efficiency of the propulsion system of an SUAV, the correct combination of all propulsion system components is critical. However, the largest impact on the maximal endurance is, arguably, caused by the propeller. The paper proposes a simple method of optimizing the propeller characteristics for hover and compares the proposed propeller design with conventional and commercially available propellers.

Low Speed Aerodynamics of Drogue System Refueling of Unmanned Aerial Vehicles

2014 ◽  
Vol 1016 ◽  
pp. 349-353 ◽  
Author(s):  
Ian R. McAndrew ◽  
Elena Navarro ◽  
Orin Godsey
Keyword(s):  
Wind Tunnel ◽  
Unmanned Aerial Vehicles ◽  
Weather Conditions ◽  
Military Strategy ◽  
Wind Tunnel Experiments ◽  
Low Speed ◽  
Significant Aspect ◽  
Aerial Vehicles ◽  
Low Speeds

Refueling aircraft has become a significant aspect of military strategy for air forces to work at further distances from safe shores. This paper will address the aerodynamics of the drogue refueling system and in particular its characteristics at low speeds, including head and tail winds. Data from wind tunnel experiments are used to show how the docking when refueling is affected by the lower speeds, position behind the supply aircraft and weather conditions. Possibilities of design improvements and implications are related to the task of refueling Unmanned Aerial Vehicles in-flight

Perching and resting—A paradigm for UAV maneuvering with modularized landing gears

2019 ◽  
Vol 4 (28) ◽  
pp. eaau6637 ◽  
Author(s):  
Kaiyu Hang ◽  
Ximin Lyu ◽  
Haoran Song ◽  
Johannes A. Stork ◽  
Aaron M. Dollar ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Power Consumption ◽  
Rapid Prototyping ◽  
Unmanned Aerial Vehicles ◽  
Reducing Power ◽  
Battery Power ◽  
Aerial Vehicles ◽  
Wide Range ◽  
Potential Applications ◽  
Time Of Operation

Perching helps small unmanned aerial vehicles (UAVs) extend their time of operation by saving battery power. However, most strategies for UAV perching require complex maneuvering and rely on specific structures, such as rough walls for attaching or tree branches for grasping. Many strategies to perching neglect the UAV’s mission such that saving battery power interrupts the mission. We suggest enabling UAVs with the capability of making and stabilizing contacts with the environment, which will allow the UAV to consume less energy while retaining its altitude, in addition to the perching capability that has been proposed before. This new capability is termed “resting.” For this, we propose a modularized and actuated landing gear framework that allows stabilizing the UAV on a wide range of different structures by perching and resting. Modularization allows our framework to adapt to specific structures for resting through rapid prototyping with additive manufacturing. Actuation allows switching between different modes of perching and resting during flight and additionally enables perching by grasping. Our results show that this framework can be used to perform UAV perching and resting on a set of common structures, such as street lights and edges or corners of buildings. We show that the design is effective in reducing power consumption, promotes increased pose stability, and preserves large vision ranges while perching or resting at heights. In addition, we discuss the potential applications facilitated by our design, as well as the potential issues to be addressed for deployment in practice.

scholarly journals Wind tunnel testing of additive manufactured aircraft components

2018 ◽  
Vol 24 (5) ◽  
pp. 886-893 ◽  
Author(s):  
Z.W. Teo ◽  
T.H. New ◽  
Shiya Li ◽  
T. Pfeiffer ◽  
B. Nagel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Wind Tunnel ◽  
Wind Tunnel Test ◽  
Cost Effective ◽  
Wind Tunnel Testing ◽  
Content Type ◽  
Wind Tunnel Measurement ◽  
Measurement Results ◽  
Joined Wing ◽  
Tunnel Testing

Purpose This paper aims to report on the physical distortions associated with the use of additive manufactured components for wind tunnel testing and procedures adopted to correct for them. Design/methodology/approach Wings of a joined-wing test aircraft configuration were fabricated with additive manufacturing and tested in a subsonic closed-loop wind tunnel. Wing deflections were observed during testing and quantified using image-processing procedures. These quantified deflections were then incorporated into numerical simulations and results had agreed with wind tunnel measurement results. Findings Additive manufacturing provides cost-effective wing components for wind tunnel test components with fast turn-around time. They can be used with confidence if the wing deflections could be accounted for systematically and accurately, especially at the region of aerodynamic stall. Research limitations/implications Significant wing flutter and unsteady deflections were encountered at higher test velocities and pitch angles. This reduced the accuracy in which the wing deflections could be corrected. Additionally, wing twists could not be quantified as effectively because of camera perspectives. Originality/value This paper shows that additive manufacturing can be used to fabricate aircraft test components with satisfactory strength and quantifiable deflections for wind tunnel testing, especially when the designs are significantly complex and thin.

scholarly journals Structural and Aeroelastic Studies of Wing Model with Metal Additive Manufacturing for Transonic Wind Tunnel Test by NACA 0008 Example

Aerospace ◽  
2021 ◽  
Vol 8 (8) ◽  
pp. 200
Author(s):  
Natsuki Tsushima ◽  
Kenichi Saitoh ◽  
Hitoshi Arizono ◽  
Kazuyuki Nakakita
Keyword(s):  
Additive Manufacturing ◽  
Wind Tunnel ◽  
Wind Tunnel Test ◽  
Wind Tunnel Testing ◽  
Manufacturing Costs ◽  
Aerospace Structures ◽  
Manufacturing Technique ◽  
Wing Model ◽  
Transonic Flutter ◽  
Transonic Wind Tunnel

Additive manufacturing (AM) technology has a potential to improve manufacturing costs and may help to achieve high-performance aerospace structures. One of the application candidates would be a wind tunnel wing model. A wing tunnel model requires sophisticated designs and precise fabrications for accurate experiments, which frequently increase manufacturing costs. A flutter wind tunnel testing, especially, requires a significant cost due to strict requirements in terms of structural and aeroelastic characteristics avoiding structural failures and producing a flutter within the wind tunnel test environment. The additive manufacturing technique may help to reduce the expensive testing cost and allows investigation of aeroelastic characteristics of new designs in aerospace structures as needed. In this paper, a metal wing model made with the additive manufacturing technique for a transonic flutter test is studied. Structural/aeroelastic characteristics of an additively manufactured wing model are evaluated numerically and experimentally. The transonic wind tunnel experiment demonstrated the feasibility of the metal AM-based wings in a transonic flutter wind tunnel testing showing the capability to provide reliable experimental data, which was consistent with numerical solutions.

Extractor X — Autonomous Tilt Rotor UAV

2013 ◽  
Vol 01 (02) ◽  
pp. 177-198 ◽  
Author(s):  
Joshua Jang En Chao
Keyword(s):  
Wind Tunnel ◽  
Unmanned Aerial Vehicles ◽  
Potential Role ◽  
Theoretical Calculations ◽  
Flight Mechanics ◽  
Tilt Rotor ◽  
Aerial Vehicles ◽  
Military Applications ◽  
Wind Tunnel Data ◽  
Near Future

This paper looks into conceptualization, implementation and validation of the potential role that hybrid quad tilt rotor unmanned aerial vehicles (UAV) may undertake in the near future, especially so in military applications. A tilt rotor is designed, built and analyzed with wind tunnel data, theoretical calculations and flight log data. In addition, the paper will discuss the flight mechanics involved during its transition from hover to forward flight. As the tandem wing tilt rotor encompasses two unconventional designs, numerous mathematical models were developed in the design of the UAV.

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