Summary of 8. ONR YIP Final Presentation - Morphing Wing Design - Moulton

In the presentation led by Ben Moulton, the focus is on the design and testing of 3D printed morphing wings intended to eliminate the need for a vertical stabilizer in aircraft. The presentation covers several key technological concepts and product features:

Key Concepts and Features:

Morphing Mechanism: The design aims to control yaw using a morphing wing mechanism, which utilizes conformal (parabolic) flaps instead of traditional articulated flaps. This design minimizes flow separation and enhances aerodynamic efficiency.
3D Printing Methodology: The manufacturing process employed is Fused Deposition Modeling (FDM), commonly known as 3D Printing. Key benefits highlighted include:
- Repeatability: Identical parts can be produced from the same STL file.
- Replicability: Other users can produce the same parts using shared files and settings.
- Speed: Rapid prototyping allows for quick iterations during the design phase.
- Cost-Effectiveness: Materials like PLA are relatively inexpensive, enabling affordable prototyping.
- Durability: With proper design, 3D printed components can withstand the stresses of flight.
Design Iterations: A total of 18 designs were conceptualized, with two main designs selected for testing:
- Arcs Mechanism: Utilizes a compliant airflow design with a simple structure.
- Kinks Mechanism: A more advanced design featuring fully 3D printed components that maintain airfoil shape during deflection.
Testing and Validation: The presentation details various tests conducted to validate the designs:
- Airfoil Testing: Evaluating the ability to achieve the desired parabolic shape and deflection range.
- Load Testing: Ensuring the structure can handle up to 4G loads.
- Fatigue Testing: Assessing the durability of the mechanisms over numerous cycles.
- Wind Tunnel Simulation: Using a car window to simulate flight conditions and observe the behavior of the wings.
Design Criteria: The morphing mechanism was designed to achieve:
- A deflection range of ±20 degrees.
- Durability for at least one flight cycle (600 movements).
- Adherence to structural load limits.

Lessons Learned:

Importance of material compatibility in bi-material prints.
Optimal skin thickness for structural integrity.
The impact of design on the mechanical behavior of the wing during flight.

Conclusion:

The project successfully demonstrated the ability to create a morphing wing design that meets the outlined criteria, with the Kinks design being favored for its performance in controlling yaw. The final design showcased was capable of achieving the desired deflection and structural integrity.

Main Speakers/Sources:

Ben Moulton (Primary Presenter)
Dr. Hunsaker (Contributed to the discussion on parabolic flaps)
Zach (Mentioned in relation to yaw control methodology)

Notable Quotes

— 18:43 — « The biggest way to sum up my research was that we were moving fast and breaking stuff. »