Final Report Summary - GBSSD(3) (Ground Based Structural & Systems Demonstrator Phase 3 - Component and sub-system manufacture)
Executive Summary:
The GBSSD3 program is an ongoing area of research aimed at developing the capability and understanding of Natural Laminar Flow (NLF) for the next generation of civil aircraft. It is undertaken in support of the Smart Fixed Wing Aircraft (SFWA) program to mature a NLF technology stream for a future short range transport aircraft and is intended to support the TRL process by the design, manufacture, test and demonstration of an integrated NLF wing leading edge assembly, as a Ground Based Demonstrator (GBD).
The NLF aerofoil coupled with improved aero-smoothness, offers higher efficiencies in aerodynamic performance and a reduction in drag, contributing to an overall increase in an aircraft’s efficiency. This in turn allows for potential reductions in aircraft emissions by reducing fuel burn. Achieving these reductions would be a significant step towards reaching the ACARE goals for 2020, including a 50% reduction in CO2 emissions and an 80% reduction in NO emissions.
The requirements of a NLF wing differ significantly from a conventional turbulent wing, requiring changes to the architecture of the wing, the aerofoil definition, the detailed design concepts and manufacturing processes. The aerodynamic performance of a natural laminar flow wing is highly dependent on meeting very high aero-smoothness tolerances including steps and gaps, surface roughness and surface waviness tolerances, in the regions where laminar flow is to be maintained.
Project Context and Objectives:
Final Project Report Overview
GKN produced Final Project Report ‘Clean Sky JTI-CS-2011-01-SFWA-02-015’, containing all the information from early development to completion of NLF Ground Based Structure and System Demonstrator. This report details the outputs from the Clean Sky GBSSD Phase 2 - baseline and Phase 3 - innovative programme of work, undertaken by the GKN Aerospace Services Limited Composite Technology Centre (CTC) in Bristol.
The baseline leading edge design is based on a concept design, down-selected and developed as part of GBSSD Phase 2. It incorporates a CFRP composite leading edge skin and attachment angles, metallic leading edge ribs, electro-thermal Wing Ice Protection System (WIPS), and an electroformed Nickel Erosion Shield. Initially the conceptual design delivered in GBSSD Phase 2 is taken through a detailed design loop to reach a C maturity design standard, with models, drawings and DFM data created to allow component manufacture. This information is generated for both Krueger Bay 4 and Krueger Bay 5 areas of the leading edge and is referred to as the Baseline Design. The baseline design is then used for the manufacture of the Krueger bay 4 leading edge components only.
GBSSD Phase 3 (innovative) design was developed to the same design standard as the baseline design, but using a selection of more innovative technologies, identified and selected as part of an Innovative Down- Selection Gate Review held during the program. This design is used to produce a Krueger bay 5 design, complementing the baseline design and demonstrating an alternative leading edge solution. Technologies investigated include; a novel leading edge architecture and materials and low TRL manufacturing processes such as Additive Layer Manufacturing (ALM).
The innovative design was only produced for the Krueger 5 leading edge assembly.
Two previous Call for Proposal (CfP) phases have been completed; Phase 1, considering the development of span-wise joining techniques and a wing ice protection system (WIPS) and Phase 2, a detailed design of a fully integrated leading edge zone. In Phase 1, the problem of how to achieve step and joint tolerance requirements for the LE to upper wing box cover interface, of sufficient quality to support natural laminar flow was investigated by GKN.
Mechanical joint concepts were evaluated against a very tight set of criteria, focusing on steps and gaps, surface finish, aerofoil profile, waviness and fastening techniques. Phase 2 involved the concept design of a fully integrated LE zone, specifically Krueger bay sections 4 and 5, and form the basis for further development of the concepts in GBSSD Phase 3.
GBSSD3 is a continuation of this work, aimed at delivering a set of desk-top demonstrator components that can evaluate the GBSSD NLF design and demonstrate the integration of the key systems required in an NLF leading edge solution.
Initially the conceptual design delivered in GBSSD2 is taken through a detailed design loop to reach a C maturity design standard, with models, drawings and DFM data created to allow component manufacture. This information is generated for both Krueger Bay 4 and Krueger Bay 5 areas of the leading edge and is referred to as the Baseline Design. The baseline design is then used for the manufacture of the Krueger bay 4 leading edge components only.
A second design is developed to the same design standard as the baseline design, but using a selection of more innovative technologies, identified and selected as part of an Innovative Down-Selection Gate Review held during the program. This design is used to produce a second Krueger bay 5 design, complementing the baseline design and demonstrating an alternative leading edge solution. Technologies investigated include; a novel leading edge architecture and materials and low TRL manufacturing processes such as Additive Layer Manufacturing (ALM).
The innovative design will only be produced for the Krueger 5 leading edge assembly, from which the components required for assembly will be manufactured.
The developed of both leading edge designs focuses on a number of key technology areas:
· Innovative Wing Leading Edge Ribs and Integrated Leading Edge Cover solutions
· Krueger kinematic mechanism integrated with LE fixed structure
· Continued Investigations on potential Wing Ice Protection (WIPS) solutions
· Lightning Strike protection for the Leading Edge zone
· Assessment of Bird strike requirements in the presence of a Krueger Flap System
· Novel Leading Edge Architectures to address waviness concerns
· Innovative leading edge material combinations to reduce weight
All components are supplied to Clean Sky to support the assembly of a 4.3m spanwise section of flight representative leading edge installation, including all movables and sub-systems.
The demonstrator aims to validate that the GBSSD LE design can be manufactured to the required standard appropriate to a civil short range aircraft, and to the required level of aerosmoothness needed to achieve Natural Laminar Flow.
The installation will include a span-wise joint and an integral spar cap, a representative forward wing spar and representative wing-box upper and lower cover sections. Both leading edge skin panels will include a state of the art wing ice protection system (WIPS) and a designated erosion protection strategy.
Project Results:
Six substantial engineering reports have been issued with the results of GBSSD Phase 3 (See project
deliverables):
13CTC00001PFR Iss3 Bolting demo report
CRC-R-0091 Issue 1_BLADE LE Bird Strike Analysis
DEV8658 - WIPS Delivery Report
Technical ReportNCC.TMP.010 V3
WS00001414-NDT-1
GBSSD3 Final project Report Released
Potential Impact:
The manufacture, flight test, and certification of a Composite Natural Laminar Flow Wing marks two important milestones. Firstly it would indicate that the advantages posed by composite materials are being fully exploited and allow for the next generation of wing design to fly. Secondly it would significantly contribute to the reduction in fuel consumption and CO2 emissions.
List of Websites:
http://www.gkn.com(opens in new window)
The GBSSD3 program is an ongoing area of research aimed at developing the capability and understanding of Natural Laminar Flow (NLF) for the next generation of civil aircraft. It is undertaken in support of the Smart Fixed Wing Aircraft (SFWA) program to mature a NLF technology stream for a future short range transport aircraft and is intended to support the TRL process by the design, manufacture, test and demonstration of an integrated NLF wing leading edge assembly, as a Ground Based Demonstrator (GBD).
The NLF aerofoil coupled with improved aero-smoothness, offers higher efficiencies in aerodynamic performance and a reduction in drag, contributing to an overall increase in an aircraft’s efficiency. This in turn allows for potential reductions in aircraft emissions by reducing fuel burn. Achieving these reductions would be a significant step towards reaching the ACARE goals for 2020, including a 50% reduction in CO2 emissions and an 80% reduction in NO emissions.
The requirements of a NLF wing differ significantly from a conventional turbulent wing, requiring changes to the architecture of the wing, the aerofoil definition, the detailed design concepts and manufacturing processes. The aerodynamic performance of a natural laminar flow wing is highly dependent on meeting very high aero-smoothness tolerances including steps and gaps, surface roughness and surface waviness tolerances, in the regions where laminar flow is to be maintained.
Project Context and Objectives:
Final Project Report Overview
GKN produced Final Project Report ‘Clean Sky JTI-CS-2011-01-SFWA-02-015’, containing all the information from early development to completion of NLF Ground Based Structure and System Demonstrator. This report details the outputs from the Clean Sky GBSSD Phase 2 - baseline and Phase 3 - innovative programme of work, undertaken by the GKN Aerospace Services Limited Composite Technology Centre (CTC) in Bristol.
The baseline leading edge design is based on a concept design, down-selected and developed as part of GBSSD Phase 2. It incorporates a CFRP composite leading edge skin and attachment angles, metallic leading edge ribs, electro-thermal Wing Ice Protection System (WIPS), and an electroformed Nickel Erosion Shield. Initially the conceptual design delivered in GBSSD Phase 2 is taken through a detailed design loop to reach a C maturity design standard, with models, drawings and DFM data created to allow component manufacture. This information is generated for both Krueger Bay 4 and Krueger Bay 5 areas of the leading edge and is referred to as the Baseline Design. The baseline design is then used for the manufacture of the Krueger bay 4 leading edge components only.
GBSSD Phase 3 (innovative) design was developed to the same design standard as the baseline design, but using a selection of more innovative technologies, identified and selected as part of an Innovative Down- Selection Gate Review held during the program. This design is used to produce a Krueger bay 5 design, complementing the baseline design and demonstrating an alternative leading edge solution. Technologies investigated include; a novel leading edge architecture and materials and low TRL manufacturing processes such as Additive Layer Manufacturing (ALM).
The innovative design was only produced for the Krueger 5 leading edge assembly.
Two previous Call for Proposal (CfP) phases have been completed; Phase 1, considering the development of span-wise joining techniques and a wing ice protection system (WIPS) and Phase 2, a detailed design of a fully integrated leading edge zone. In Phase 1, the problem of how to achieve step and joint tolerance requirements for the LE to upper wing box cover interface, of sufficient quality to support natural laminar flow was investigated by GKN.
Mechanical joint concepts were evaluated against a very tight set of criteria, focusing on steps and gaps, surface finish, aerofoil profile, waviness and fastening techniques. Phase 2 involved the concept design of a fully integrated LE zone, specifically Krueger bay sections 4 and 5, and form the basis for further development of the concepts in GBSSD Phase 3.
GBSSD3 is a continuation of this work, aimed at delivering a set of desk-top demonstrator components that can evaluate the GBSSD NLF design and demonstrate the integration of the key systems required in an NLF leading edge solution.
Initially the conceptual design delivered in GBSSD2 is taken through a detailed design loop to reach a C maturity design standard, with models, drawings and DFM data created to allow component manufacture. This information is generated for both Krueger Bay 4 and Krueger Bay 5 areas of the leading edge and is referred to as the Baseline Design. The baseline design is then used for the manufacture of the Krueger bay 4 leading edge components only.
A second design is developed to the same design standard as the baseline design, but using a selection of more innovative technologies, identified and selected as part of an Innovative Down-Selection Gate Review held during the program. This design is used to produce a second Krueger bay 5 design, complementing the baseline design and demonstrating an alternative leading edge solution. Technologies investigated include; a novel leading edge architecture and materials and low TRL manufacturing processes such as Additive Layer Manufacturing (ALM).
The innovative design will only be produced for the Krueger 5 leading edge assembly, from which the components required for assembly will be manufactured.
The developed of both leading edge designs focuses on a number of key technology areas:
· Innovative Wing Leading Edge Ribs and Integrated Leading Edge Cover solutions
· Krueger kinematic mechanism integrated with LE fixed structure
· Continued Investigations on potential Wing Ice Protection (WIPS) solutions
· Lightning Strike protection for the Leading Edge zone
· Assessment of Bird strike requirements in the presence of a Krueger Flap System
· Novel Leading Edge Architectures to address waviness concerns
· Innovative leading edge material combinations to reduce weight
All components are supplied to Clean Sky to support the assembly of a 4.3m spanwise section of flight representative leading edge installation, including all movables and sub-systems.
The demonstrator aims to validate that the GBSSD LE design can be manufactured to the required standard appropriate to a civil short range aircraft, and to the required level of aerosmoothness needed to achieve Natural Laminar Flow.
The installation will include a span-wise joint and an integral spar cap, a representative forward wing spar and representative wing-box upper and lower cover sections. Both leading edge skin panels will include a state of the art wing ice protection system (WIPS) and a designated erosion protection strategy.
Project Results:
Six substantial engineering reports have been issued with the results of GBSSD Phase 3 (See project
deliverables):
13CTC00001PFR Iss3 Bolting demo report
CRC-R-0091 Issue 1_BLADE LE Bird Strike Analysis
DEV8658 - WIPS Delivery Report
Technical ReportNCC.TMP.010 V3
WS00001414-NDT-1
GBSSD3 Final project Report Released
Potential Impact:
The manufacture, flight test, and certification of a Composite Natural Laminar Flow Wing marks two important milestones. Firstly it would indicate that the advantages posed by composite materials are being fully exploited and allow for the next generation of wing design to fly. Secondly it would significantly contribute to the reduction in fuel consumption and CO2 emissions.
List of Websites:
http://www.gkn.com(opens in new window)
