Periodic Reporting for period 3 - PRODIGE (PRediction of aerOdynamics and hinge moment loaDs at hIgh mach and fliGht rEynolds number)
Okres sprawozdawczy: 2021-04-01 do 2021-09-30
PRODIGE contributes to the Airframe ITD of the Clean Sky 2 program. PRODIGE designed the experimental setup of a cryogenic wind tunnel test campaign on a scale model of a business jet with the objective to generate accurate loads and hinge moment measurements. At this end, PRODIGE designed and built a cryogenic 1/16 scale model of a business jet equipped with a hinge moment balance. This last one has been designed as a full integral part of the WT model wing, and has been tested and calibrated to work in cryogenic conditions. It has been used to generate experimental loads and hinge moments at High Mach and flight Reynolds numbers.
The overall objective of PRODIGE is to support the development of methods to increase aerodynamic performance and efficiency, leading to positive ecological impact, less fuel consumption, thus less operating costs and more affordable flights, all resulting in a benefit for the society and in the enhancement of European competitiveness.
The overall objective of PRODIGE is to support the development of methods to increase aerodynamic performance and efficiency, leading to positive ecological impact, less fuel consumption, thus less operating costs and more affordable flights, all resulting in a benefit for the society and in the enhancement of European competitiveness.
The preliminary design of the local balance aimed at accurately measuring the aileron hinge moment was completed in November 2018 by TUDA. However, technical discussions between PRODIGE and the TM, focusing on design aspects related to balance features and balance-wing integration, led to a significant extension of the design review with the TM. In fact, at the end of the first period, different solutions involving wing-integral or aileron-integral balance arrangements were still under discussion.
An agreement has been found with the TM on the best architecture in terms of potential performance and safety, consisting in a wing-integral balance able to account for wing bending and torsion effects on the balance measurements.
The preliminary design of the model has been then completed by IBK and assessed in the Preliminary Design Review in September 2019.
The connection of the interchangeable ailerons to the aileron balance (fitting strategy), has been validated through laboratory leakage tests: at ambient conditions in DEHARDE in June 2019, and at cryogenic conditions at TUDA in July 2019.
Extensive analysis, and reiterated design loops needed to ensure proper accuracy of the aileron balance (that means flexibility of the sensing element) and, at the same time, suitable strength to ensure the structural safety, have been completed in the first months of 2020. The full WT model detail design has been frozen in April 2020 and then assessed and accepted by the TM in the CDR in May 2020.
All the WT model parts have been manufactured by DEHARDE. The wing has been delivered to TUDA in October 2020 to start with the aileron balance calibration.
The test rig to calibrate the aileron balance has been designed and implemented by TUDA. The balance calibration started in November 2020 at ambient conditions. The calibration in cryogenic conditions started in January 2021, with modified covers, and it has been completed at end of March 2021. The calibration at ambient conditions was repeated in April due to the aileron covers replacement, and it lasted till end of April 2021. Due to unexpected results in terms of repeatability of measurements during calibration, a further inspection after tests revealed a debonding of the SGs on the balance.
This issue, together with the very tight schedule before the delivery of the model to ETW, led to the agreement of re-instrumenting the aileron balance for WT tests and postponing the calibration after the productive test campaign in ETW.
WT model and test requirements have been extensively discussed with TM and ETW both during first and second periods: after many iterations, the test slot at ETW was reserved from the 21st of June to the 3rd of July 2021. The model was delivered to ETW during week #21 and the WT test campaign was performed successfully in the slot 21st June to 3rd July 2021 without any criticality.
The calibration was performed by TUDA according to the agreed schedule and calibration results were used by IBK to recover the aileron hinge moments in all the WT conditions. Results were discussed with ETW and TM on 20th September 2021.
An agreement has been found with the TM on the best architecture in terms of potential performance and safety, consisting in a wing-integral balance able to account for wing bending and torsion effects on the balance measurements.
The preliminary design of the model has been then completed by IBK and assessed in the Preliminary Design Review in September 2019.
The connection of the interchangeable ailerons to the aileron balance (fitting strategy), has been validated through laboratory leakage tests: at ambient conditions in DEHARDE in June 2019, and at cryogenic conditions at TUDA in July 2019.
Extensive analysis, and reiterated design loops needed to ensure proper accuracy of the aileron balance (that means flexibility of the sensing element) and, at the same time, suitable strength to ensure the structural safety, have been completed in the first months of 2020. The full WT model detail design has been frozen in April 2020 and then assessed and accepted by the TM in the CDR in May 2020.
All the WT model parts have been manufactured by DEHARDE. The wing has been delivered to TUDA in October 2020 to start with the aileron balance calibration.
The test rig to calibrate the aileron balance has been designed and implemented by TUDA. The balance calibration started in November 2020 at ambient conditions. The calibration in cryogenic conditions started in January 2021, with modified covers, and it has been completed at end of March 2021. The calibration at ambient conditions was repeated in April due to the aileron covers replacement, and it lasted till end of April 2021. Due to unexpected results in terms of repeatability of measurements during calibration, a further inspection after tests revealed a debonding of the SGs on the balance.
This issue, together with the very tight schedule before the delivery of the model to ETW, led to the agreement of re-instrumenting the aileron balance for WT tests and postponing the calibration after the productive test campaign in ETW.
WT model and test requirements have been extensively discussed with TM and ETW both during first and second periods: after many iterations, the test slot at ETW was reserved from the 21st of June to the 3rd of July 2021. The model was delivered to ETW during week #21 and the WT test campaign was performed successfully in the slot 21st June to 3rd July 2021 without any criticality.
The calibration was performed by TUDA according to the agreed schedule and calibration results were used by IBK to recover the aileron hinge moments in all the WT conditions. Results were discussed with ETW and TM on 20th September 2021.
the expected impact of PRODIGE lies within three major areas:
• European competitiveness;
• Society and Environment;
• Innovation and knowledge integration.
The magnitude of the expected impact can be appreciated considering the envisaged, but realistic, advantages to improve aerodynamic efficiency of aircraft in transonic conditions. These aspects have a reasonable impact in terms of direct and indirect costs, making the aircraft of new generation a competitive product because the correct prediction of the loads and hinge moment in transonic conditions will allow defining the right structure for the airplane, without weight excess.
Indeed, PRODIGE is contributing to the reduction of certification costs by reducing wind tunnel testing and by developing new design approach strongly based on the data generated in this project. The project is supporting the WP A.1-4 AIRFRAME strategy devoted to enhance the adoption of virtual modelling in the design processes for certification purpose. In particular, the project will contribute to improve the loads and efficiency prediction of control surfaces at High Mach and flight Reynolds numbers.
Moreover, the PRODIGE project offers the opportunity to enlarge the area of interest to other Clean Sky IADP work programmes enabling technologies for other applications aiming to maximise the synergies between different aircraft configurations. Military, civil, fixed wing transports, short, medium, and long-range vehicles are just some examples of the wide spectrum of use of the Project outcomes within the aerospace sector.
A direct positive impact for the different partners is given by the exploitation. IBK has a strong motivation to continue increasing the visibility and competitiveness of their design capability by displaying their innovative methods and means to design complex WT models. TUDA is increasing its recognition at European level as an excellent university partner capable of performing research but also of successfully designing accurate complex balances working in critical conditions. DREAM is gaining more visibility providing support in the correct evaluation of the loads and hinge moment in a pilot-project that is recognized EU-wide. Finally, DEHARDE is an industrial partner that for the first time is involved in a research project funded by the European Commission. Although it has already a long tradition (more than 50 years) and an international recognition in the manufacturing of complex tailor-made wind tunnel models, DEHARDE has decided to participate to the PRODIGE project by contributing with their knowhow to the improvement of the model manufacturing. This is extending their visibility from the industrial field to the applied research world.
Each partner involved in the project have the opportunity to further increase their know-how transferring the IPs generated in this project into own core business.
Furthermore, IBK, together with DREAM and TUDA are also supporting universities by giving lectures. This impact goes beyond technical benefits/ impacts and produces social benefits by transferring knowledge to next generations of engineers.
Finally, PRODIGE will also help protecting and developing highly skilled jobs in aeronautics and its supply chain, including academia, ROs and SMEs; against a backdrop of significantly increased global competition.
• European competitiveness;
• Society and Environment;
• Innovation and knowledge integration.
The magnitude of the expected impact can be appreciated considering the envisaged, but realistic, advantages to improve aerodynamic efficiency of aircraft in transonic conditions. These aspects have a reasonable impact in terms of direct and indirect costs, making the aircraft of new generation a competitive product because the correct prediction of the loads and hinge moment in transonic conditions will allow defining the right structure for the airplane, without weight excess.
Indeed, PRODIGE is contributing to the reduction of certification costs by reducing wind tunnel testing and by developing new design approach strongly based on the data generated in this project. The project is supporting the WP A.1-4 AIRFRAME strategy devoted to enhance the adoption of virtual modelling in the design processes for certification purpose. In particular, the project will contribute to improve the loads and efficiency prediction of control surfaces at High Mach and flight Reynolds numbers.
Moreover, the PRODIGE project offers the opportunity to enlarge the area of interest to other Clean Sky IADP work programmes enabling technologies for other applications aiming to maximise the synergies between different aircraft configurations. Military, civil, fixed wing transports, short, medium, and long-range vehicles are just some examples of the wide spectrum of use of the Project outcomes within the aerospace sector.
A direct positive impact for the different partners is given by the exploitation. IBK has a strong motivation to continue increasing the visibility and competitiveness of their design capability by displaying their innovative methods and means to design complex WT models. TUDA is increasing its recognition at European level as an excellent university partner capable of performing research but also of successfully designing accurate complex balances working in critical conditions. DREAM is gaining more visibility providing support in the correct evaluation of the loads and hinge moment in a pilot-project that is recognized EU-wide. Finally, DEHARDE is an industrial partner that for the first time is involved in a research project funded by the European Commission. Although it has already a long tradition (more than 50 years) and an international recognition in the manufacturing of complex tailor-made wind tunnel models, DEHARDE has decided to participate to the PRODIGE project by contributing with their knowhow to the improvement of the model manufacturing. This is extending their visibility from the industrial field to the applied research world.
Each partner involved in the project have the opportunity to further increase their know-how transferring the IPs generated in this project into own core business.
Furthermore, IBK, together with DREAM and TUDA are also supporting universities by giving lectures. This impact goes beyond technical benefits/ impacts and produces social benefits by transferring knowledge to next generations of engineers.
Finally, PRODIGE will also help protecting and developing highly skilled jobs in aeronautics and its supply chain, including academia, ROs and SMEs; against a backdrop of significantly increased global competition.