Presentation Title

Method of Creating Non-Linear Compound Curve with Hot Wire Foam Cutting for Rapid sUAS Prototyping

Faculty Mentor

Dave Berger

Start Date

18-11-2017 10:45 AM

End Date

18-11-2017 11:00 AM

Location

9-247

Session

Engineering/CS 3

Type of Presentation

Oral Talk

Subject Area

engineering_computer_science

Abstract

In an effort to quickly and efficiently prototype wing designs for the PRANDTL-M (PReliminary AerodyNamic Design To Land on Mars) aircraft, research into using a hot wire foam cutter was carried out. Hot Wire foam cutting is achieved by drawing a taut wire heated with an electric current which is used for cutting through foam blocks. This method lends itself well to linear shapes and simple curves. PRANDTL-M relies on a unique aerodynamic wing twist which is non-linear. To overcome the obstacle of cutting this non-linear twist into a foam block, a process was developed which loads the foam with inverse twist, allowing for a strait wire to cut the wing profile. Unloading the resulting cut produces a flyable wing with proper twist parameters. Drawing board to flight testing of sUAS wing time was reduced from several months to a few weeks. Small design tweaks not involving change in the overall twist profile or span could be performed within a few days, and once a design was chosen, several copies could be rapidly produced. Testing allowed for better predictions of expected proper CG locations and early identification and verification of aircraft flight characteristics. Ultimately, this process allowed for aero-coefficients to be calculated prior to expending effort on a mold for more precise carbon fiber versions.

Summary of research results to be presented

Method of rapidly prototyping Non-Linear Compound Curved airfoils was carried out and proved successful in decreasing time from design to flight test. Additionally it lowered the overall cost of project in both man-hours and capital. Ultimately, aero-coefficients were able to be computed using data from aircraft built with this method, which reduced program risk in mold investment.

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Nov 18th, 10:45 AM Nov 18th, 11:00 AM

Method of Creating Non-Linear Compound Curve with Hot Wire Foam Cutting for Rapid sUAS Prototyping

9-247

In an effort to quickly and efficiently prototype wing designs for the PRANDTL-M (PReliminary AerodyNamic Design To Land on Mars) aircraft, research into using a hot wire foam cutter was carried out. Hot Wire foam cutting is achieved by drawing a taut wire heated with an electric current which is used for cutting through foam blocks. This method lends itself well to linear shapes and simple curves. PRANDTL-M relies on a unique aerodynamic wing twist which is non-linear. To overcome the obstacle of cutting this non-linear twist into a foam block, a process was developed which loads the foam with inverse twist, allowing for a strait wire to cut the wing profile. Unloading the resulting cut produces a flyable wing with proper twist parameters. Drawing board to flight testing of sUAS wing time was reduced from several months to a few weeks. Small design tweaks not involving change in the overall twist profile or span could be performed within a few days, and once a design was chosen, several copies could be rapidly produced. Testing allowed for better predictions of expected proper CG locations and early identification and verification of aircraft flight characteristics. Ultimately, this process allowed for aero-coefficients to be calculated prior to expending effort on a mold for more precise carbon fiber versions.