FINAL PRELIMINARY DESIGN Middle of Market Transport Team 2 Submitted By: Ryan Burke, Michael Cleek, Paige Dumke, Brandon Goss, Ryan McGill, Anthony Ragusa, Andrew Willard The Pennsylvania State University Aerospace 402A Dr. James Coder Contents 1.0 Final Configuration .................................................................................................................................. 2 1.1 Three-View Drawing ........................................................................................................................... 2 1.2 Wing Configuration ............................................................................................................................. 2 1.3 Fuselage Configuration ....................................................................................................................... 4 1.4 Empennage Configuration .................................................................................................................. 6 2.0 Aircraft Specifications ............................................................................................................................. 6 3.0 Weight Analysis ....................................................................................................................................... 9 3.1 Mission Sizing ...................................................................................................................................... 9 3.2 Comprehensive Weight Analysis....................................................................................................... 10 3.3 Composite Structures ....................................................................................................................... 12 4.0 Airfoil & Wing Aerodynamics ................................................................................................................ 14 4.1 Maximum Lift Coefficient and Lift Curve .......................................................................................... 14 4.2 High Lift Devices ................................................................................................................................ 17 5.0 Performance ......................................................................................................................................... 17 5.1 Drag Build-Up .................................................................................................................................... 17 5.2 Thrust Requirements ........................................................................................................................ 21 5.3 Propulsion System............................................................................................................................. 23 5.4 Climb Parameters.............................................................................................................................. 27 5.5 Takeoff and Landing Analysis ............................................................................................................ 28 6.0 Stability Analysis ................................................................................................................................... 31 6.1 Longitudinal Static Stability............................................................................................................... 31 6.2 Stability Requirements ...................................................................................................................... 33 7.0 Cost Estimates ....................................................................................................................................... 34 Concluding Statements ............................................................................................................................... 36 References .................................................................................................................................................. 37 Appendix ..................................................................................................................................................... 39 A. Additional Figures and Tables ......................................................................................................... 39 B. Advanced Composite Materials Trade Study .................................................................................. 40 C. MATLAB Scripts ............................................................................................................................... 42 1 1.0 Final Configuration 1.1 Three-View Drawing 162 ft 142 ft 1.2 Wing Configuration Wing Area To size the wing, one looks to the takeoff constraints. In this case, takeoff dictates the minimum wing size. To obtain a takeoff wing size a few assumptions were made. Assuming the maximum lift coefficient and approach speed are the same as the 757-200 (giving the same airport reference code) and based on the weight, wing area and approach speed of a 757-200, one can find its maximum lift coefficient to be 2.8. Thus, with the two assumptions specified, one can obtain the takeoff wing sizing from Equation 1.1. 2WTO 2 stall cLmax Slanding = ρV 2 (1.1) It is important to note that the takeoff weight is used to define the landing wing area in case of emergency landing immediately after takeoff. The constraint on the wing area for landing is a minimum of S landing = 2240 ft2. With the landing constraint in mind looking to cruise coefficient can help to size the wing. For maximum range, πΆπΏ 1/2 should be maximized. Differentiating, setting equal to zero, and assuming a drag polar as shown πΆπ· in Equation 1.2, obtains the optimum lift coefficient expression for cruise, shown in Equation 1.3. CD = CD0 + CLopt = (CL −CL0 )2 (1.2) πe0 AR 2kCL0 +√4k2 CL0 2 −(16k)(−kCL0 2 −CD0 ) 6k where k = 1 πe0 AR (1.3) From Equation 1.3, one can see that the optimum lift coefficient is a strong function of the lift coefficient at zero angle of attack, πΆπΏ0 . Also, from the drag polar, one can see that the drag coefficient decreases with increasing CL0 . By setting the landing wing area equal to the wing area at cruise, the optimum lift coefficient in cruise can be obtained. With a cruise wing area of 2240 ft2 and πΆπΏ0 = 0.35 (See cruise lift curve) a CLopt of 0.511 was obtained. Wing Span Once the wing area is specified, one can obtain other wing characteristics. By holding the aspect ratio constant at AR = 9, a span of 142.0 ft can be obtained by applying Equation 1.4. π = √π΄π ∗ π (1.4) With span specified a mean aerodynamic chord (MAC) can be obtained by using the equation for chord as a function of span for a wing with a single linear taper (Equation 1.5) and the definition of mean aerodynamic chord (Equation 1.6). The MAC obtained is 18.11 ft. 2π π(π¦) = (1+π)π [1 − 2 2(1−π) |π¦|] π π/2 2 ππ΄πΆ = ∫0 π π ππ¦ (1.5) (1.6) A typical mid-sized transport taper ratio of λ=0.2 and the MAC can then be used to determine the tip chord (ct) and root chord (cr) via Equations 1.7 and 1.8, respectively. ππ = 3ππ΄πΆ π+1 (π2 +π+1) 2 (1.7) ππ‘ = πππ (1.8) The values of the obtained root and tip chord respectively are found to be 26.0 ft and 5.0 ft. 3 Aspect Ratio Based on existing aircrafts, an aspect ratio can be chosen to best match the mission requirements. In this case, an aspect ratio of 9 was chosen and held constant throughout the wing sizing process. This was based on the aspect ratios of both Boeing 757-200 and 787. It was also chosen as 9 to reflect use of composites, much like the Boeing 787. Fuel Tanks Since the fuselage has little room to spare after fitting the payload requirements, the fuel for the flight must be held elsewhere, mainly inside the wing structure. From Nicolai and Carichner Chapter 8.6, they provide fuel densities and packaging factors for several different fuels and tanks. This transport will presumably have integrated tanks in the wings and wing box to contain the 103,000 lbs. of fuel. This translates to a fuel tank volume of 2760 ft3. The fuel used for this calculation was JP-8, a common jet fuel. However, by 2025 and beyond, the use of natural gas and fuels may be limited, so it’s always a possibility a new fuel source may be utilized. It can be concluded that tanks capable of holding 1380 gallons should be present in both wings. 1.3 Fuselage Configuration The final design fuselage configuration remained the same as in previous iterations. It will feature a singleaisle with three seats on each side. Primary reasons for choosing a narrow-bodied aircraft was a belief that there would be less drag than a wide-body aircraft, which increases performance. Since this design is carrying 220 passengers it falls within the range of multiple narrow-body passenger capacities. The length of the fuselage was determined to be 162 Ft. This was the minimum length that will be able to accommodate all 220 passengers in two classes (First and Economy) and other various necessities such as lavatories (8), exit aisles (4), the cockpit, nose cone and finally the empennage (see Table 1.1 for fuselage length build-up). Windows on the fuselage will be located at every 40 inches (Nicolai) down the fuselage primarily in the seating sections of the aircraft. Figure 1.1 provides an inboard profile view of the fuselage and demonstrates how the lengths in Table 1.1 were utilized. Table 1.1 Fuselage Length Build-Up Component Length Quantity Radome 4 ft 1 Cockpit 8 ft 1 First Class Row (seat Pitch) 38 in. 6 Economy Class Row (seat pitch) 32 in. 33 Exit Areas 6 ft 4 Empennage 20 ft 1 Total Length 4 Total Length [ft] 4 8 19 88 24 20 162 Figure 1.1 Interior View of Fuselage The cockpit would presumably feature a state-of-the-art avionics and flight control system. Aircraft systems today are almost fully digital or “fly-by-wire” and the advances in this technology could possibly make the cockpit smaller or make other aspects of the aircraft more efficient like weight, volume, etc. For now, this is not a primary concern for the scope of this preliminary design. Figure 1.2 depicts the designed cross section for the economy class. This is the critical design area because the economy class is made to be the most volume efficient, and therefore drives cabin diameter for at least the top of the fuselage. The first class seating arrangement will consist of a 2-2 per row configuration to have a more comfortable seating option in the aircraft. Figure 1.2 Aircraft Economy Class Cross Section (From Jetsizer-II Excel Workbook) 5 The cargo hold is located beneath the cabin floor, also seen in Figure 1.2 which must be able to contain approximately 3520 ft3 for the specified passengers, (based on 225 passenger and cargo assumption, and volume assumption from Nicolai text). The most volume efficient and lightest option for containers was found to be (20) LD-3 size containers with a combined volume of 3520 ft3. These containers have overall dimensions of 5.3 x 6.6 x 5 ft (searates.com) where the width falls within width of the lower fuselage. 1.4 Empennage Configuration Once the wing design was also completed, the tail design began since the wing drives the tail design. The tail functions as a counter mechanism to the wing, to create a downforce behind the aircraft’s neutral point to eliminate the nose up pitching moment the lift of the wing creates. It also allows for control surfaces to be implemented, elevators on the horizontal tail and a rudder the vertical tail provides aircraft stability and control in both longitudinal and lateral/directional axes. This preliminary report does not include the elevator and rudder sizing, but instead the surface areas for the vertical and horizontal tail. As most passenger transports today, including the chosen parent aircraft use a “conventional” configuration for the tail surfaces. This includes two horizontal fins on each side of the fuselage somewhere mid-tail cone, and the vertical tail is located on the fuselage’s centerline on the top surface. This configuration allows for larger horizontal tails sizes and best control authority because the engines are mounted below the wings. There is no extra weight added to the current design because the fuselage already exists for the tail to be mounted on. In addition, a conventional style tail reduces the stress on the vertical tail as opposed to mounting the horizontal stabilizer onto the vertical stabilizer. In turn, the vertical tail is smaller which keeps the weight of the aircraft lower. In the interim design, it was assumed that the aerodynamic centers of both the horizontal and vertical tail airfoils were located at the same distance in respect to the wing aerodynamic center. This was later dealt with when performing C.G and neutral point calculations, and for stability it was determined the horizontal moment arm would be equal to 80 ft and the vertical tail moment arm equal to 75 ft. This changed the required tail areas and therefore multiple other parameters. See Section 2.0 for more information on the tail sizing. 2.0 Aircraft Specifications Below is a list of all relevant parameters for this design. Note that much of these values are subject to change once the next phase of design is started, so values are given with little precision and are to be treated as estimates. Table 2.1 Aircraft Specifications Variable Value Units WTO Wfuel Wfixed Wempty lbs. lbs. lbs. lbs. Parameter Weight Gross Weight (Maximum Take-Off) Fuel Weight Fixed Weight Empty Weight 6 281005 103480 51075 126451 Wing Sizing Wing Area - Landing Wing Area - Cruise Wing Span Root Chord Tip Chord Mean Aerodynamic Chord Local Airfoil Aerodynamic Center Taper Ratio Sweep Angle Thickness Ratio Effective Cruise Mach Landing Max Clean Lift Coefficient Cruise Max Clean Lift Coefficient Landing Lift Curve Slope Cruise Lift Curve Slope Wing Sizing Aspect Ratio Efficiency Cruise Wing Loading Take-Off Wing Loading Optimum Lift Coefficient Average Cruise Weight High Lift Devices Double Slotted Fowler c'/c Sflapped/S Sweep Angle, High Lift Delta Max Lift Coefficient Krueger Sflapped/S Delta Max Lift Coefficient Slanding Scruise b ππ ππ‘ MAC XAC 2240 2076 142 26 5 18.11 4.53 ft2 ft2 ft ft ft ft ft ο¬ Λ t/c Meff_cr 0.20 30 0.14 0.69 1.74 1.4 0.10 0.30 degrees degrees-1 degrees-1 9 0.6 109.25 psf CLmax, landing CLmax, cruise CLα, landing CLα, cruise AR eo π π πππ’ππ π π π ππ πΆπΏπππ‘ ππππ’ππ πππ£π 135.38 psf 0.319 226758 lbs. Λ HL οCLmax 1.3 0.5 20.3 0.878 degrees - οCLmax 0.8 0.203 - 2 52,200 0.312 93.6 132.2 97 lbs. (lbs._m/hr)/lbs._f in in in Engines Number of Engines Power (Thrust) Rating Specific Fuel Consumption Fan Diameter Length Width/Diameter SFC 7 Horizontal Tail Area Span Root Chord Tip Chord Mean Aerodynamic Chord Taper Ratio Aspect Ratio SHT bHT πππ»π ππ‘π»π MAC ο¬ AR 561 50.26 11.17 3.69 8.43 0.33 4.5 ft2 ft ft ft ft - Vertical Tail Area Span Root Chord Tip Chord Mean Aerodynamic Chord Taper Ratio Aspect Ratio SVT bVT ππππ ππ‘ππ MAC ο¬ AR 385 24.02 16.01 5.28 12.55 0.33 1.5 ft2 ft ft ft ft - 29194 17.33 14.42 162.83 1 38 33 6 8.33 20 3.5 ft3 ft ft ft ft ft ft ft/s Vstall, landing Vstall, cruise 774.17 0.8 177.78 401.6 Vmin power, SL Vmin power, cruise 366 717 ft/s ft/s 593 5897 43627 45217 16 ft/s nmi ft ft min Fuselage Sizing Pressurized Volume Fuselage Width Fuselage Height Fuselage Length Number of Aisles Total Number of Rows Economy Rows First Class Rows Cockpit Length Empennage Radome Performance Cruise Speed Cruise Mach Number Stall Speed (Landing) Stall Speed (Cruise) Maximum Endurance Velocity at Min. Power, Sea Level Velocity at Min. Power, Cruise Maximum Range Max Velocity, Sea Level Maximum Cruise Range Service Ceiling Absolute Ceiling Time to Climb Vcruise Mcruise 8 ft/s ft/s 3.0 Weight Analysis 3.1 Mission Sizing As previously stated in the initial design report, maximum take-off weight, WTO, was determined by summing the Wfixed, Wempty, and Wfuel. Fixed weight consists of the weight of the 7 crew members and 220 passengers, assuming a weight of 225 lbs. for each individual, which yields 51,075 lbs.. This weight is viewed as constant through our calculations. For fuel weight, calculations can be seen below. Ultimately, fuel weight was found to be a function of take-off weight, which was found through iterations to be 0.3498*WTO. Regarding empty weight, Equation 3.1 is also found to be a function of take-off weight. From Table 5.1 in the Nicolai and Carichner text, constants a and b for a transport aircraft are 0.911 and 0.947, respectively. Wempty = aWTO b (3.1) Fuel weight is expressed as several ratios at each segment during the mission profile. This is because fuel is burned consistently during flight and the ratios at take-off will not equal that of the ratios at descent or landing. (Nicolai) For example, the ratio of the weight after take-off to the initial weight is equal to 0.975, while the ratio of weight after ascending to 32,000 feet to the weight after the take-off is equivalent to 0.97. For a turbojet, the weight ratio for cruise can be found below in Equation 3.2. R=C V TSFC L W ln(Wi ) D f (3.2) Figure 3.1 Designed Mission Profile From the Mission Profile in Figure 3.1 above, the range is close to 5000 feet and each phase of the mission requires different amounts of fuel. In Table 3.1 below, the fuel burn during segments can be seen using the range equation to compare the initial weight with the final weight of each segment. 9 Table 3.1 Mission Profile Mission Segment Fuel Burn (W_n+1/W_n) Segment Weight (lbs..) n=1 n=2 0.975 n=1 281005 n=2 n=3 0.97 n=2 273980 n=3 n=6 0.70649 n=3 265760 n=6 n=7 1 n=6 187756 n=7 n=8 0.98251 n=7 187756 n=8 n=9 1 n=8 184472 n=9 n=10 1 n=9 184472 n=10 184472 Final Weight 3.2 Comprehensive Weight Analysis More Detailed weights include Landing Gear, Starting Systems, Surface Controls, Flight Instruments, Furnishings, and AC and Icing instruments. These weight estimations came from the several following empirical Equations (3.3-3.7) which were found in the Nicolai & Carichner text, Chapter 20.2.1. WLanding Gear = 62.21 ∗ (. 01WTO )0.84 (3.3) WStarting system = 38.93(2 ∗ WENG ∗ .01)0.918 (3.4) WSurface Controls = 56.01(WTO ∗ qMAX ∗ .0001)0.576 (3.5) WFlight Instruments = 2 ∗ (15 + .032 ∗ (. 01 ∗ WTO ) + 4.8 + .006 ∗ (. 01 ∗ WTO ) + .15 ∗ (. 01 ∗ WTO )) WAC and Anti−Icing = 469.3(Volume ∗ 227 ∗ .001)0.419 (3.6) (3.7) The other detailed weights include the weight of the furnishing on the aircraft included the flight deck, passenger seats, lavatories, buffet stations, oxygen system, windows, cargo holdings, and miscellaneous. Structure weights included the planform weight, fuselage weight, and the tail weight, all adjusted for using advanced composite materials (see section 3.3 for more details of how this was done). After calculating these, Table 3.2 below shows the detailed weights of the furnishings and the sum of them all. Engine weight is found from manufacturing data. Table 3.2 Comprehensive Weight Analysis Component Weight (lbs.) Systems 10 % TOGW Starting System 719 0.26% Integrated Fuel Tanks 3347 1.19% C.G Control System 304 0.11% Engine Controls 67 0.02% 6662 2.37% Flight Instruments 51 0.02% Engine Instruments 14 0.005% Miscellaneous Instruments 49 0.02% Electrical 2503 0.89% Air Conditioning & Anti-Icing 7138 2.54% Flight Deck 275 0.26% Passenger Seats 7047 1.19% Lavatories 1448 0.11% Food Provisions 2387 0.02% O2 System 316 2.37% Windows 6954 0.02% Cargo Provisions 813 0.005% Cargo Containers 3748 0.02% Miscellaneous Furnishings 254 0.89% Fuselage 18552 6.6% Landing Gear 8095 2.9% Planform 20505 7.3% Empennage 11250 4.0% Control Surface Hydraulics & Pneumatics Furnishings Structures 11 Engines & Nacelles 23954 8.5% Crew & Attendants 1575 0.6% Passengers 49500 17.6% Mission 97271 34.6% Reserve 5174 1.8% Trapped 1035 0.4% 281005 100% Payload Fuel TOTAL 3.3 Composite Structures When designing an advanced mid-sized transport aircraft, it is important to examine the use of advanced materials to reduce weight of the airplane structures. A trade study on the benefits and penalties of the use of composites in the construction of a modern aircraft was conducted and found that there are three main advantages to the use of composite structures. They are weight savings, maintenance savings, and increased lifespan. The conclusion of the trade study shows that using composite materials has more benefits than using typical aluminum materials for the airplane structure. Continuing concerns over the current cost of production for advanced materials have been raised, but the team feels as though cost will decrease as production increases, so that composite materials will significantly benefit our airplane design. For reference, the trade study can be found in Appendix B. Previous calculations for the weight of the structure were adjusted for the implementation of composites materials. The empty weight was reduced by 17% and the gross takeoff weight was reduced by 15%. Table 3.3 below shows in detail how the empty weight was adjusted for composites. The reduction percentages in Table 3.3 were chosen directly from chapter 20 of Nicolai & Carichner’s text. Components Planform Empennage Fuselage Landing Gear Table 3.3 Weight Corrections for Advanced Composite Materials %Reduction Weight (lbs.) Without Composites 0% 25631 With Composites 20% 20505 Without Composites 0% 15000 With Composites 25% 11250 Without Composites 0% 24736 With Composites 25% 18552 Without Composites 0% 8742 12 All Else Empty Engines With Composites Without Composites With Composites Without Composites 8% 0% 2% 0% Revised Empty Weight Empty Weight Reduction Takeoff Gross Weight Reduction 8095 44757 44095 23954 126450 17% 15% Composites are a combination of materials mixed together to achieve specific structural properties, the independent materials in composites do not dissolve or merge completely but rather act together as one. These materials generally consist of a fibrous material embedded in a resin matrix that is laminated with fibers oriented in alternating directions. This structure helps establish strength. Different strength for a desired direction can be produced by changing the fiber orientations for layers in a laminate. Carbon Fiber Reinforced Polymer is an extremely strong and light fiber-reinforced plastic. It is often comprised of carbon fibers and a binding polymer. It can be made by heating the fibers, typically aramid (Kevlar), to ~2000ºC in an oxygen-deprived oven. These fiber end up being approximately 6μm (six micrometers) in diameter and spun into a thread. These threads are then woven into sheets and mixed with hardening resins, such as epoxy or silica, to form the various material needs. The manufactured composite laminate is known to have the high strength to weight ratio as well as rigidity, which lends itself to be very applicable to the aerospace industry. Looking at our parent aircraft, the Boeing 787, carbon fiber reinforced polymer is used in the fuselage, wings, empennage, and other various parts of the aircraft as seen in Figure 3.2. The Boeing 787 uses approximately 50% composite materials by weight. This percentage is the largest by far of any Boeing commercial airplane use in composite materials. Compared to an all-aluminum approach, the Boeing 787 saves about 20% of weight while full. The composite material usage does not only cut down on the weight saved, but also on the maintenance required, both scheduled and nonscheduled. This can be seen in the more experiences Boeing 777, which has approximately 12% composites. Compared to the 767 aluminum tail, the 777 composite tail is approximately 25% larger, while requiring about 35% less maintenance. Apart from the tail, the 777 incorporates a composite floor beam in all 565 airplanes. In the 10 years of flying, none of the 777’s needed a composite floor beam to be replaced. Even if there is repair needed on a composite component, the same process is used – with bolted repairs. There is also the option to perform bonded composite repairs, which keeps the airplane’s aerodynamic and aesthetic finish. This rapid composite repair technique will allow these airplanes to get back into the air faster than an aluminum airplane. Another technique that Airbus is implementing is the use of composite panels, instead of full composite bodies. This allows for a whole new panel to be installed for the broken panel. This method is faster in many cases. Issues with composite materials are that they do not have visible cracks unlike metals and often can be missed by simple inspection. In addition, composite materials are very porous in nature and collect moisture caused stresses and strains inside the material. The stresses can cause delamination, or composite layer separation. Many non-destructive inspection are used to see if the material is close to failure. Such procedures include ultrasonic, X-ray, moisture detector, and audible sonic testing. 13 Figure 3.2 Boeing 787 Material Composition [modernairliners.com] 4.0 Airfoil & Wing Aerodynamics 4.1 Maximum Lift Coefficient and Lift Curve To obtain the maximum lift coefficients at cruise and landing conditions, two-dimensional lift curves were obtained for each case. The cruise lift curve was obtained using Xfoil at landing conditions, which correspond to an effective Mach number of 0.1747 (a landing speed of 137 knots) and a Reynold’s number of 26,007,742. The resulting two-dimensional lift curve can be seen in Figure 4.1. Figure 4.1 Lift curve of SC2-0714 at sea level conditions. It can be noted that Xfoil likely overestimated the higher end of the lift curve. Estimating that the maximum lift coefficient probably occurs somewhere around a Cd=0.0250, a corrected Clmax of 2.21 can be obtained. This maximum lift coefficient occurs at α=15 degrees. From this value, a three-dimensional CLmax of 1.72 was obtained using Equation (4.1). 14 πΆπΏπππ₯ = 0.9πΆππππ₯ cos (π¬π ) (4.1) 4 Likewise, the two-dimensional lift curve was able to be obtained for cruise conditions from figures of NASA Technical Memorandum 4044. Noting that for small angles the airfoil lift coefficient, Cl, is approximately equal to the normal force coefficient, Cn, the lift curve at cruise conditions (Meff=0.70 and Re=40 x 106) is given and can be seen in Figure 4.2 Figure 4.2 Lift curve of SC2-0714 at cruise conditions. To find CLmax at cruise altitude, a Mach number for CLmax was obtained from Equation (4.2), where the subscript “cruise” indicates conditions at cruise speed. MCLmax = Mcruise √CLcruise 1.2 (4.2) The Mach number for maximum lift coefficient is 0.417, which corresponds to a Reynold’s number of 18,048,022. This condition was then used in Xfoil to obtain a Clmax of 1.79. Again, using Equation (4.2), a CLmax of 1.40 was obtained. To approximate the full wing lift curve, the wing lift curve slope was found by Equation (4.3). AR CLα = Clα (AR+2) (4.3) The two dimensional lift curve slope was obtained from the linear region of the airfoil lift curve and was 0.118 deg-1 for sea level and 0.155 deg-1 in cruise. Also, by fitting a line to the linear region of the lift curve, an angle of attack for zero lift can be obtained, which is the same for infinite aspect ratio as it is for a finite aspect ratio. The angle of attack for zero lift, α0L, is approximated to be -4.95 degrees. Using this 15 information, three-dimensional lift curve slopes were obtained, their values being 0.096 deg-1 and 0.127 deg-1 respectively. The effect of aspect ratio on the wing lift curve slope can be seen in Figures 4.3 and 4.4. Figure 4.3 Lift curve of SC2-0714 with Infinite AR vs. AR=9 at Sea Level. Figure 4.4 Lift curve of SC2-0714 with Infinite AR vs. AR=9 in Cruise. 16 4.2 High Lift Devices By adding double slotted Fowler flaps, ΔCLmax at sea level increases by 0.878, which was calculated using Equation (4.4) and noting that Equation (4.5) gives the ΔCLmax for double slotted Fowler flaps. Here, c’ is the new chord with flaps extended, which was chosen to be a 30 percent increase from the base chord (c’/c=1.3). c’ ΔCLmax = 1.6 ∗ c ΔCLmax = 0.9ΔClmax Sflapped Splanform (4.4) cos(ΛHL ) (4.5) The sweep angle of the fowler flaps was calculated to be 20.3 degrees by Equation (4.6) to satisfy the 30 percent increase in chord. Also, it was assumed that the flapped area was approximately 50 percent of the planform area. 4 1−λ tan(Λ HL ) = tan(Λ LE ) − [0.7 (4.6) ] AR 1+λ Likewise, by adding Kreuger flaps along 80 percent of the span and applying Equation (4.5) with Kreuger flaps contributing a ΔClmax of 0.3, CLmax was increased by 0.203. With the high lift devices deployed the new ΔCLmax at sea level is 2.82. 5.0 Performance 5.1 Drag Build-Up Drag contributions were contributed to profile drag for the wing, fuselage, and tail, the induced drag cause by the wing, and finally trim drag from the tail. Each component of drag was calculated individually across the speed range at both sea level and cruise altitudes. Then, they were summed to find the total drag across the aircraft, Figs. 5.1 and 5.2 are the resulting drag force curves with respect to velocity. For Figures of drag contributions to the total drag, see Appendix A. 17 Figure 5.1 All Drag versus Velocity Curves across Sea Level Speed Range Figure 5.2 All Drag versus Velocity Curves across Cruise Altitude Speed Range 18 Profile Drag The profile drag at sea level conditions was obtain using Xfoil and varying Mach number and Reynold’s number. These values were then run at the corresponding lift coefficient needed for that speed to obtain the speed’s section drag coefficient. Using the drag Equation (5.1), the profile drag was obtained. The results of this can be seen in Figures 5.1. 1 Dprofile = 2 ρV 2 SCdprofile (5.1) The profile drag at a cruise altitude of 35,000 feet was obtained from NASA Technical Paper 2890. Again, speed was varied and matched with a given Cn (Cn ≈ Cl for small α) to obtain the section drag coefficients. Equation (5.1) was applied to obtain the total profile drag. The results can be seen in Figure 5.2. Fuselage Drag The fuselage drag was one of the more complicated drags to calculate, considering changing Reynolds number along the length of the fuselage and different equations for skin friction coefficients due to changing Reynolds number. A MATLAB script was written to deal with the complexities of the fuselage drag, but also for the other drags. See Appendix B for the complete drag build-up script. The total length and correct cross section of the aircraft was inputted into the Jetsizer-II workbook and produced nine different points along the fuselage, dividing it into ten sections. This was done to use surface areas between the ten sections of the aircraft to calculate the drag. Then the Reynolds number was calculated for every location of the fuselage at every velocity in the speed range. The script was written to determine if either Equations (5.2) or (5.3) should be used for skin friction coefficient. Finally, the drag at every velocity was found using Equation (5.4). 1 CfLaminar = 1.328Re−2 (5.2) Cf Turbulent = 0.455Re−2.58 (5.3) Where π e = ρVx μ and transiton Re ≅ 500,000 DFuselage = ∑π 0.5ρV 2 Swi Cfi (5.4) Tail Profile Drag Difficult to determine without a tail airfoil selected, the profile drag of the horizontal and vertical stabilizers was estimated by taking the ratio of surface area between the tail and wing. This served as a correction factor to the wing profile drag coefficient and it was decided to use these to find the tail drag. Of course, this is an extremely crude approximation, but comparing to the Jetsizer-II workbook, the tail drags were of similar magnitude. Induced Drag Induced drag is a result of the wing creating the necessary pressure difference between upper and lower surfaces in order to produce lift, hence the term ‘induced’ drag. Furthermore, it is directly related to the lift coefficient of the aircraft as seen in Equation 5.5. 19 C2 L CDi = πeAR (5.5) Since CL is already a function of velocity squared, it is squared again in the induced drag coefficient. Then, CDi is multiplied by velocity squared when finding total induced drag, therefore, the total induced drag should be inversely proportional to velocity squared and this is evident in Figures 5.1 and 5.2. The induced drag is the largest contributor to the aircraft drag. Trim Drag Trim drag is the consequence of the tail providing a down force with a backwards component to cancel the aircraft nose-up pitching moment. Although it is a necessary evil, it should only account for 1-10%) of the total drag of the aircraft (Nicolai & Carichner). Using a free body diagram of the aircraft in trimmed flight, the lift coefficient for the tail required to obtain trimmed flight can be find as seen in Equation 5.6. S CLt = S l (cΜ Cmac + xCL ) (5.6) t t Where the reference areas of the wing and tail appear, along with tail moment arm, lt , mean aerodynamic chord, cΜ , and moment coefficient about the wing aerodynamic center, Cmac. Trim drag coefficients were then calculated from the derived formula of Equation 5.7. S CLt CDtrim = S t [ CLt eAR CL CL et ARt − 2] CDi (5.7) It is clear the trim drag is dependent on wing and tail parameters, and more importantly the induced drag coefficient which was found beforehand. The trim drag at both altitudes were 5% and 4% of the total drag and therefore were considered to be within reasonable magnitude. Total Drag Each component of drag were combined and the result is shown in Figures 5.1 and 5.2. Critical information L from these figures include the D max L at both altitudes as well as the D at cruise velocity. Lift to drag ratios are at a maximum at minimum drag, therefore the lowest points on the drag curve are where the values in Table 5.1 are derived from. The maximum lift to drag ratios were considered reasonable for an advanced mid-size transport, but it is thought that these values still have potential to increase, especially the cruise L/D which reflects the efficiency of the aircraft and should be optimized. Table 5.1 Lift to Drag Ratios Taken From Drag Curve Sea Level L/D max=23.7 L/D max=20.4 Cruise (35,000 Ft.) L/D cruise=15.9 There are still many other forms of drag that were not accounted for in this preliminary analysis. Base, interference, and transonic wave drag are some of the other forms of drag that could have a significant impact on the values in Table 5.1, and therefore the design. Although the drag force will most likely increase, with further analysis and detail design the wings may be able to produce more lift than expected, or be optimized to reduce induced drag, trim drag, or others. 20 5.2 Thrust Requirements For a constant altitude, the thrust of the aircraft is limited by the thrust available while being required to overcome the drag at certain velocities. The thrust required for the aircraft is dependent on the total drag build up from Figure 5.1 and 5.2. The drag buildup for a third altitude was also calculated to show a better analysis of altitude variation for thrust. The mid-cruise altitude of 10,000 feet was used to find a third drag build up, which was expected to fall in between the sea level and cruise curves. The thrust available for this aircraft is dependent on the constraint diagram and thrust needed to take off. Therefore, the thrust available to ensure the mission can be executed was 52,200 lbs. per engine at sea level. The static thrust available for a constant altitude is equal to the original thrust available multiplied by the ratio of the air density at that altitude over the air density of sea level. So the original 104,000 lbs. at takeoff and sea level decreases to 74% that value at 10,000 feet and 31% that value at 35,000 feet. The actual thrust available would experience a slight decrease in this value as airspeeds increase, until it approaches the maximum speed wherein it increases again. From the calculated thrust required from the drag build up and the thrust available given by the engine and air density, the thrust curves for each of the altitudes can be found in Figures 5.3, 5.4 and 5.5. Figure 5.3 Thrust Requirement Curve for Sea Level 21 Figure 5.4 Thrust Requirement Curve for 10,000 ft Figure 5.5 Thrust Requirement Curve for 35,000 ft 22 5.3 Propulsion System To size the propulsion system many parameters must be taken into account. To start the thrust to weight ratio for the take-off, cruise, landing stall speed and service ceiling need to be found and graph compared to wing loading to find the ideal engine size. Stall speed is the first parameter found and the calculation is relatively simply. To find the stall speed we took Equation (5.8) and manipulated it to solve for wing loading at stall speed, which produced Equation (5.9). 1 2 L = W = 2 ρVmax SCLmax W S VS ( ) (5.8) 1 2 2 = ρVmax SCLmax (5.9) This value will set the right side limit of the constraint diagram. Everything to the left of this wing loading value will be in the acceptable range and meet the requirements set forth by the limiting stall speed. Next the thrust to weight ratio for cruise is calculated to and graphed against wing loading as wing loading increases. Starting with Equation (5.10), where ππππ₯ is the velocity during cruise, and breaking down πΆπ· into component form we can get the following Equation (5.11) which is a manipulated thrust to weight equation for cruise. 1 TSL σ = 2 ρV2max SCD 1 2 (5.10) 2 πππΏ π = πππππ₯ π (πΆπ·0 + πΎ ∗ [ 2 2π ) ] 2 πππππ₯ π (5.11) Finally after rearranging Equation (5.12), the thrust to weight ratio during cruise can be compared to the wing loading. TSL ) W Vmax ( 2 = ρ0 Vmax CD0 1 W S 2( ) + 2K W ( ) ρσV2max S (5.12) Next, the thrust to weight ratio during take-off needs to be accounted for. This will most likely set the lower limit of the thrust to weight ratio needed to properly size the engines. Starting with the modified take-off distance Equation (5.13), found from Mohammad Sadraey's report "Preliminary Aircraft Design" where πΆπ·πΊ = (πΆπ·ππ − ππΆπΏππ ) and πΆπΏπ = πΆπ·ππ = πΆπ·0 + πΆπ·0 ππ + πΆπ· 0 πππππ 2ππ 2 ππππππ’ππ π , the T/W value for take-off can be found. Noting that and keeping in mind the average values for πΆπ·0 ππ and πΆπ· 0 πππππ are 0.008 and 0.005 respectively, also found in Sadraeys's report, the equation can be manipulated to solve for T/W and we get Equation (5.14). 1.65W STO = ρgSC DG 23 T −μ W CD −μ− G W CL R ln[ T ] (5.13) T (W) STO (μ−(μ+ = CD 1 0 )[exp(0.6ρgC S D0 TO W )]) CL R S 1 (5.14) 1−exp(0.6ρgCD0 STO W ) S This gives us a close to linear line when graphed and becomes the lower limit for operational thrust to weight limits allowed within the design constraints. Finally the thrust to weight ratio for the service ceiling is calculated. Using the rate of climb, Equation (5.15) and solving for π/π we get Equation (5.16). ROC = T (W) = Pavl −Preq ROC 2 W ( ) √ √CD0 S ρ (5.15) W + 1 (5.16) L ( ) D max K To relate this to the service ceiling we use a π ππΆ equal to 100 ft/min and alter the equation to include the ratio or densities at the giving service ceiling altitude, π. This now gives us Equation (5.17). This is another critical equation in deciding the thrust to weight ratio needed for engine size selection as the ratio needs to be above this curve for the aircraft to meet the requirements. T (W) sc = ROC 2 W σ ( ) √ √CD0 S ρ + 1 L σ( ) D max (5.17) K Pulling all these equations together and using the known values we are able to plot these four equations, via Matlab, all on the same graph and therefore find the ideal thrust to weight ratio needed, seen in Figure 5.6. 24 Figure 5.6 Propulsion Design Constraint Diagram The region in Figure 5.6 that is in between the four different curves is the ideal thrust to weight ratio region and the designated design space for our engine. We chose a value for π/π of 0.325, the upper limit above where the service ceiling and take-off π/π intersect. This π/π ratio of 0.325 gives us a needed thrust of 91,326 lbs. for our take-off weight of 281,005 lbs. Using a two engine set up this means we need about 45,663 lbs. of thrust for each engine. This value now means we are going to look for a lightweight fuel-efficient engine that can provide at least this amount of thrust per engine. After research, the Pratt & Whitney PW4152 is the engine that most fits our requirements. With 52,200 lbs. of thrust per engine this is plenty of power to fly our plane. Intentionally oversizing the engines slightly leads to greater safety in case one were to fail and the SFC is actually lower for this engine than many other engines with a thrust closer to our ideal value. Overall this engine will provide the thrust required for all elements of flight and provides our team with a resourceful and cost effective efficient turbofan engine. 25 Engine Specs The engine chosen for our aircraft design is the Pratt & Whitney PW4152. Two engines will be implemented into our design, each with a thrust of 52,200 lbs. and specific fuel consumption (SFC) of 0.312. More specification of the PW4152 can be found in Table 5.2, as well as an image of the engine in Figure 5.7. Table 5.2 Engine Specifications Manufacturer Pratt & Whitney Units Model PW4152 - Applications A310-324/-324ET/-324F - Weight 9,213 [lb] Thrust 52,200 [lbf] SFC 0.312 [lb/lbf hr] Fan Diameter 93.6 [in] Length 132.2 [in] Width/Diameter 97 [in] Figure 5.7 PW4152 Engine Image 26 5.4 Climb Parameters From the thrust requirement curves for the three different altitudes, the rate of climb of the aircraft can be found. The rate of climb is a function of excess power, which is found by the velocity multiplied by the difference between the thrust available and the thrust required. The high available thrust available of sea level allows for the most excess power at a speed above take off velocity. Therefore, at sea level the rate of climb is around 2939 ft/min. As altitude increases, the rate of climb decreases to 708 ft/min at the cruise altitude. This data is plotted in Figure 5.8, in order to find the service ceiling and absolute ceiling limits. Rate of Climb vs. Altitude 3500 Rate of Climb (ft/min) 3000 2500 2000 1500 1000 500 0 0 5 10 15 20 25 30 35 40 45 50 Altitude (1e10 ft) Figure 5.8 Rate of Climb From this data in Figure 5.8, the service ceiling can be found as the altitude at which the rate of climb is 100 ft/min. Thus, the service ceiling is defined at 43,627 feet. The absolute ceiling is similarly found as the altitude for which the rate of climb is 0 ft/min. The absolute ceiling was found at 45,217 feet. Both these ceilings are limits and consequently larger than the mission requirements of 43,000 feet ceiling. Yet, these values being relatively close to the mission requirements ensures the aircraft is operating efficiently. The time of climb to the cruise altitude from sea level uses the rate of climb and distance needed to be climb. From Figure 5.8, the time to climb to cruise without any other maneuvers or restrictions would be approximately 16 minutes. Although this is relatively short, the excess power granted from the engines at the altitudes leading up to the desired 35,000 feet allows for the higher rate of climb. A shorter time of climb value is optimal for decreasing profile drag, but is limited by the rate of climb to prevent excess fuel consumption. 27 5.5 Takeoff and Landing Analysis Take off distance is the sum of ground distance, rotation distance, transition distance, and climb distance. These values all depend on various aircraft properties such as stall velocity, coefficient of lift, coefficient of drag, etc. The following Equations (5.18-5.21) pertain to values used in the takeoff estimation for this aircraft. g (T − D − μ(WTO − L)) WTO acceleration = VTO = 1.2Vstall = 1.2 ∗ √ 2 ∗ WTO ρSREF CLmax βCDG = βCDflaps + βCDgear + βCDi VTO SG = ∫ 0 2 d(V 2 ) VTO ≈ 0.5 2a a (5.18) (5.19) (5.20) (5.21) There are several ways to estimate the takeoff ground distance for an airplane. This estimation procedure assumes the acceleration is constant, and equal to the value at V = 0.707 V_TO. Using Equation (5.18), it is possible to find the ground acceleration of the airplane, which is found to be 9.5 feet per second, when the airplane is at 0.707 velocity take-off. The takeoff velocity is found using Equation (5.19), incorporating the stall speed at sea level. For this aircraft, the maximum lift coefficient during takeoff is 2.6, then the takeoff speed is calculated to be 240 feet per seconds. This speed is consistent with our parent aircrafts. The lift and drag are changing as the velocity changes, so to calculate these values, these coefficients are needed. The initial lift coefficient is 0.49 and incorporating double fowler flaps, we can increase this value to 1.37 as a maximum lift coefficient. The drag coefficient is calculated using the initial drag coefficient and changes due to flaps, gear, and induced drag. This is represented in Equation 5(5.20). These values can be found in figure 9.25 and 10.5 in Nicolai for the flaps and gear respectively. The induced drag can be calculated using the new value of coefficient of lift with the given flap setting. The coefficient of drag is found to be 0.2 for this aircraft during takeoff at sea level. Equation (5.21) is then used to calculate the ground roll distance which was found to be 5896 feet. The next distance can be calculated using Equation (5.22) below. This is the rotation distance in which the aircraft is (still on the ground) rotated to an angle of attack in such the coefficient of lift is now 0.8 ΔCLmax . After this rotation, the coefficient of lift will have a value of 2.1 for this aircraft. This distance is estimated to take 2 seconds and is calculated to be 482 feet. SR = (2 seconds) ∗ VTO (5.22) STR = Rsin(θCL ) (5.23) R= 2 VTO 0.152g Rate of Climb θCL = sin−1 ( ) VTO 28 (5.24) (5.25) SCL = (hobsticle − hTR ) tan(θCL ) (5.26) Equation (5.23) estimates the transition distance. This is the distance that the aircraft flies a constantvelocity arc with a radius R. The radius can be calculated in Equation (5.24) and was found to be almost 12000 feet. The angle of climb can be estimated from the rate of climb, which is 3400 feet per minute. The angle of climb is calculated to be about 7 degrees, using Equation (5.25). Using Equation (5.23), the distance for transition is calculated to be 1378 feet. At the end of this takeoff phase, the airplane is at a height of 160 feet. This value is greater than the given FAA requirement for an obstacle, 35 feet. Figure 5.9 describes a takeoff trajectory. Figure 5.9 Schematic for Takeoff Analysis (Nicolai) Therefore, Equation (5.26) is not needed, as we are above the climb needed and the climbing distance is zero feet. The takeoff distance can be seen in Table 5.3 below. The sum of the takeoff distances gives the total distance to be 7756 feet. This value is just under the 7800 feet takeoff requirement. Table 5.3 Take off Distance for different thrust amounts Thrust Amount Full SG 5896 feet SR 482 feet STR 1378 feet SCL 0 feet STOTAL 7756 feet The landing distance is defined as the horizontal distance required to clear a 50 foot obstacle, free roll, and then break to complete stop. Figure 5.10 below show the schematic for landing. The velocity over the 50 foot obstacle is assumed to be 1.3 Vstall, or 228 feet per second. The touchdown velocity is assumed to be 1.15 Vstall, or 202 feet per second. The weight of the aircraft is assumed to be when half the fuel is burned, or 231,172 pounds. The coefficient of lift for landing is assumed to be the maximum value with engaged flaps and slats in the landing configuration. The lift coefficient is 2.82 for the landing coefficient. 29 Figure 5.10 Schematic for Landing Analysis (Nicolai) The sum of the air distance, free roll distance, and braking distance is the estimation of the total landing distance. The air distance uses the relationship between kinetic and potential energy. It can be calculated using Equation (5.27) below. This Equation utilizes the lift and drag of the airplane. The lift can be assumed as the weight of the landing airplane. The drag can be calculated using Equation (5.28). The coefficient of drag must be altered due to drag effects of the flaps, gears, and changing induced drag. The coefficient of drag is calculated to be 0.346, and this is represented in Equation (5.29) below. The air distance can now be calculated to be 774 feet. 2 2 L V50 − VTD (5.27) SA = ( − hobsticle ) D g D = q50 SREF CD (5.28) CD = CD0 + CDi + βCDflaps + βCDgear (5.29) The free roll distance is the distance covered while the pilot reduces the power to idle, retracts the flaps, deploys the spoilers, and applies the brakes. These adjustments change the values of the thrust and the drag coefficient. The thrust can then be assumes to be zero and the coefficient of drag is updated to be about 0.353. Free roll is assumed to last 3 seconds and it is represented in Equation (5.30) below. SFR = (3 seconds)VTD (5.30) The braking distance can be calculated using Equation (5.31) below. The acceleration can be calculated using Equation (5.32), where R is the reverse thrust. For this estimation, thrust is assumed to be zero while breaking, and the reverse thrust is neglected for now. The coefficient of drag is also calculated to be 0.353 for a landing configuration that does not retract the flaps during free roll. This is done using Equation (5.33). The deceleration can then be calculated as 6 feet per second. If the pilot does retract the flaps during free roll, the coefficient of drag is 0.17. The deceleration can be calculated to be 3 feet per second. After substitution and manipulations, Equation (5.31) can be simplified to Equation (5.34) to find the braking distance. The breaking distance without retracting the flaps is 8070 feet. The breaking distance with retracting the flaps is 9274 feet. d(V 2 ) 2a V2 TD 0 SB = ∫ 30 (5.31) 1 a = ( ) (T − D − μ(L − WL ) − R) m (5.32) CD = CD0 + CDi + βCDflaps + βCDgear + βCDmisc + CDspoilers (5.33) WL SB = gμρSREF (( CD ) − CLG ) μ ln (1 + ρ SREF CD 2 ( − CLG ) VTD ) 2 WL μ (5.34) The total landing distance is the sum of the air distance, free roll distance, and braking distance. During the free roll the pilot has the option to retract the flaps and slats to decrease lift, so that the total landing distance is calculated to be 10980. If the pilot does not, the coefficient of drag remains high and the total braking distance is 9777 feet. While these both exceed the takeoff requirement, it is still a reasonable value for various international airport runways worldwide. While these estimates can hold close to actual values, there may be more drag available to slow the airplane down as the drag build up at sea level close to stall speed has a coefficient of drag of 0.443. Other forms of deceleration could be from reverse thrust or high energy absorption brakes. Table 5.4 below shows the landing distances below. Flaps SA SFR SB STOTAL Table 5.4 Landing Distance Retracted 1102 feet 605 feet 9274 feet 10981 feet Engaged 1102 Feet 605 Feet 8070 Feet 9777 Feet 6.0 Stability Analysis 6.1 Longitudinal Static Stability For the design to be considered airworthy, it must be able to fly safely and adhere to stability requirements set by the Federal Aviation Administration. In this preliminary design, only critical longitudinal static stability requirements were considered. This analysis required calculating the center of gravity (C.G.) location, C.G. limits, neutral point location, Static Margin, and pitch stiffness. Center of Gravity The C.G. location for this aircraft was determined from the different components' weights and moment arms in relation to the location of the mean aerodynamic chord of the wing. The weights of the wing planform, fuselage, engines, landing gears, empennage, and all else empty were found from the comprehensive weight analysis summarized in Table 3.2. 31 The moment arms for each component were dependent on the location of the component to the leading edge of the mean aerodynamic chord. The weight of the wing and engines, positioned at 55% the length of the plane, were acting at a moment arm of 40% the mean aerodynamic chord aft the leading edge. For the landing gear, the nose gear was positioned 15% the length aft the nose of the plane, with the main gear acting at 85% the total length. The weights of the fuselage and all else were positioned at 50% the length of the aircraft. For the empennage, the horizontal tail mean aerodynamic center was determined to be 80.2 feet from the mean aerodynamic center of the wing, and the distance for the vertical tail was 75.3 feet. Using these moment arms, the C.G. location was found by the ratio of each component's weight and moment arm product over the total weight of the aircraft. Therefore, the C.G. location was 4.2 feet aft the leading edge of the mean aerodynamic chord, or 23% the chord. To see the MATLAB script used to find the C.G location, refer to Appendix C. Neutral Point ππΆ The neutral point is effectively the aerodynamic center of the entire aircraft or where π = 0. Therefore, ππΌ the neutral point is where the pitch moment of the entire aircraft does not change when the angle of attack changes. For most aircraft, the neutral point location in respect to the center of gravity is critical for a design ππΆ because it relates to a very important stability derivative which also happens to be π or the “pitch ππΌ stiffness”. How the neutral point was found is by virtue of summing the longitudinal moments about the aircraft, differentiating them with respect to πΌ, setting the result equal to 0, and finally solve for the X-location of the neutral point. This process gives the result found in Equation 6.1. For this design, Equation 6.1 yields a neutral point location that is 6 Ft. aft of the leading of the mean aerodynamic chord, or 33% of the MAC. Xnp = S 1 d Xacw CLα HT CLαHT + [Mfuselage +Mnacelles ] S qSdα S CLα + HT ClαHT S (6.1) The moments of the fuselage and nacelles derivatives with respect to the angle of attack were found using two simple derived formulas that were provided. They are Equations 6.2 and 6.3, for the fuselage and nacelle respectively. Cmαfuselage =Kf Cmα W2fusemax Lfuse ScΜ 2∀ nacelles = scΜ (6.2) (6.3) The length and width and wing characteristics are variables of the fuselage pitch moment derivative. The K f coefficient is a factor from NASA Technical Report TR711 Figure 8, and estimated to be 1.6 for this design. For the nacelles the ∀ parameter is the enclosed volume of the nacelle assembly. 32 6.2 Stability Requirements After finding the neutral point location, the next step is to calculate the static margin, which is defined as the distance per percent chord of the center of gravity and the neutral point, see Equation 6.4. Usual values of static margin for a transport aircraft are between 4% and 7% (Nicolai 616). This design’s calculated static margin is equal to 9.8%, which is slightly higher than expected, and translates to a more stable, but less maneuverable aircraft. In future iterations it will be desired to reduce the static margin to increase aircraft maneuverability. SM = (hn − h) (6.4) Cmα =CLα (h−hn) (6.5) The real problem with the C.G and neutral point locations are that they are believed to be too far forward on the MAC. Typical values usually range between 25-35% of the MAC for the C.G. This is because the aircraft wants to be almost balanced about the wing aerodynamic center so that when the C.G moves it does so only slightly. The pitch stiffness is proportional to negative static margin, and is shown in Equation 6.5. For stability, the pitch stiffness must be negative along with a positive Cm0 to allow the aircraft to be stable and trim-able. Thus a positive static margin is required for stability, and ultimately the C.G may not exceed the neutral point along the MAC. Center of Gravity Limits The Limits for the center of gravity forward and aft of the aircraft can be determined by two criteria. The simpler of the two is the aft C.G. limit, which is equal to the neutral point location of the aircraft, and does not change. This is to retain a positive static margin for longitudinal stability requirements. Therefore h may not exceed 33% of the mean aerodynamic chord. . The forward limit was approximated by using a free-body diagram approach, where the C.G was moved forward and the lift forces to trim were calculated. Once the lift force on the horizontal tail became extremely large, so much that it obviously must be enlarged in order to produce such a force that was the determined forward limit of the C.G . This was about -10% of the mean aerodynamic chord, where the negative percentage means it in in fact forward of the wing. Figure 6.1 depicts these limits along with the center of gravity and neutral point locations. 33 Figure 6.1 Center of Gravity, Neutral Point and C.G. Limits at Maximum Takeoff Weight In the graphic above, 6.1, the red dashed lines indicated the forward and aft limits of the center of gravity. These seem very close, in fact the C.G is within 2 Ft. of the aft limit, and 6 Ft. of the forward limit. However, by keeping the C.G on top of the wing and almost centered on the entire aircraft, it should not move as much as the fuel is depleted. Also, this aircraft would include a water pump system to control the C.G movement as the fuel (almost a third of the weight) is removed. 7.0 Cost Estimates Table 7.1 Cost Estimation Breakdown for 100 Aircraft Produced (2 Test Aircraft) 2015 Calculations Values Engineering ($/hr) 132 Engineering 2954762015 Development Support (With Inflation) 446147015 Flight Testing (With Inflation) 43396196 Tooling ($/hr) 143 Tooling 1856700398 Manufacturing ($/hr, 2015) 114 Manufacturing 4747049450 34 Quality Control 360775758 Material and Equipment 2108005139 Engine and Avionics 2574194 Total Cost 12519410166 Cost per Aircraft 122739315 Table 7.2 Production Cost with varying Aircraft Quantity Number of Aircraft Produced Production Cost ($) Cost per Aircraft ($) 100 12,519,410,166 122,739,315 500 28,864,315,492 57,498,636 1000 43,343,200,034 43,256,686 The production cost estimation of the aircraft was calculated using the DAPCA IV Equations, taken from Nicolai and Carichner chapter 24. Items such as engineering, tooling, manufacturing, and materials have all experienced increases in “wrap rate” since 1998. To estimate this increase, Figure 24.4 from Nicolai and Carichner was utilized. Taking the linear curve fits, and entering the year 2015, the adjusted rates were able to be estimated reasonably. In doing so, it was apparent that the most expensive item, in terms of rates, was tooling. Fortunately this is a nonrecurring cost, and therefore does not drive the cost significantly higher in the long term. Factors such as development support and flight testing have been adjusted using an inflation rate of 1.46%, taken from a basic inflation calculator. In evaluating the cost in the long term, for larger orders such as 1000 production aircraft, it became apparent that the cost per aircraft largely decreases as compared to producing only 100 aircraft. This can be attributed to the nonrecurring costs such as engineering and tooling, as previously stated. In the end, the most significant factor which drives the cost of production for the aircraft is ultimately manufacturing cost. Manufacturing cost consumes an increasingly large percent of production cost as the number of orders increases. It is to be noted that “fudge factors” have not been included in this cost estimation, as it is apparent that various different composites are used in highly specific locations on the aircraft, something outside the scope of this preliminary design. With this said, the cost per aircraft will be inherently higher than the given aluminum predictions seen above. 35 Concluding Statements Team 2 started this design almost three months ago. It is fulfilling to have closed out the preliminary design phase with this report. This preliminary design served as a learning experience for seven young engineers pursuing undergraduate degrees in Aerospace Engineering. Much of the figures and values of the design presented in this report went through several iterations until finalizing the design. The project began with numerous assumptions, many which would need to be corrected and have been since, but for the means of this project, they were the only possible direction to take to begin the calculations. There is still, however, much more work to be done and a more detailed design is needed in order to have a flyable aircraft. In this detailed design, some of the prominent aircraft parameters will change such as the gross takeoff weight, length, width, and wing area of the aircraft. It is understood by Team 2 that the aircraft in its current state is most likely not at its optimum design, and has potential to be more efficient in several areas. One such area is the engine sizing; it is a general consensus among the group that the engines are too large for the mission requirements, but were chosen because no others in the market fit the design better. Very important aspects of the design vehicle not taken into any consideration are the control surfaces: elevators, rudder, and ailerons. These will be critical systems to incorporate into the aircraft and could potentially require changes in the tail and wing design. Despite these concerns, Team 2 believes strongly in this concept aircraft and has confidence that it can be a very efficient aircraft after more design features are implemented. As for the overall experience itself, it is safe to say Team 2 has obtained a great amount of knowledge about general aircraft design. If starting the design over again from right now, the design could have taken a slightly different course, and be overall better due to the newly gained experience of the team. As it turns out, the most challenging aspect of this project was dealing with assumptions and choosing parameters that were unknown for the design. Whether the values came from the parent aircraft, the textbook, or some other source, it always became a question of if these assumptions were valid to use. There was very limited test data, and much of aircraft parameters are proprietary data held by real aircraft manufacturers. This was dealt with in any way possible, and usually included one of the sources listed below. Another frequent concern was determining if calculated values were of reasonable magnitude for this aircraft. The general design philosophy assumed that it is a mid-size transport, therefore it should have roughly mid-sized values to other transport aircraft. One last note on the project challenges, and the most important one, was how to make this design a competitive solution for a 2025 entry date. 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Additional Figures and Tables Detailed Weight Breakdown By Percentage 0.9% 1.3% Structure 2.5% 2.4% 8.3% Fuel 17.9% 0.3% Payload 2.9% Propulsion 8.5% Landing Gear Start System 18.2% 36.8% Control Surface Gear Figure A.1 Comprehensive Weight Analysis Empty Weight Reduction By Including Advanced Composite Materials 180000 160000 [Weight [lbs..] 140000 120000 100000 80000 Without Composites 60000 With Composites 40000 20000 0 Planform Empennage Fuselage Landing Gear All Else Empty Total Components Figure A.2 Empty Weight Reductions 39 Sea Level Drag Contributions by Component Profile 21.2% 25.1% 1.6% Induced Trim 5.5% Tail Profile Fuselage 46.5% Figure A.1 Drag Contributions at Sea Level, values taken at L/Dmax. Cruise Altitude Drag Contribution by Component 18.4% 28.8% 1.8% Profile Induced 4.41% Trim Tail Profile Fuselage 46.6% Figure A.1 Drag Contributions at 35,000 Ft., values taken at L/Dmax. B. Advanced Composite Materials Trade Study In researching the benefits and penalties of the use of composites in construction of modern aircraft, three glaring advantages were recognized; weight savings, maintenance savings, and increased lifespan. Both Airbus and Boeing discuss the implementation of advanced composites on their new aircraft. Boeing states that, “The result is an airframe comprising nearly half carbon fiber reinforced plastic and other composites. This approach offers weight savings on average of 20 percent compared to more conventional aluminum designs”, when discussing the new 787 Dreamliner in their website magazine. Similarly, Airbus 40 claims to have seen a 20% weight reduction as a result of the new A350 XWB being constructed from 53% advanced composite materials. From this, the design team feels comfortable making the assertion that if composites are used in appropriate aspects of construction, the total weight will be able to be significantly reduced, and thus the fuel consumption as well (if all things are held equal). Along with weight reduction, advanced composite materials experience a reduced risk of corrosion and fatigue. Airbus asserts that, “By applying composites on the A350 XWB, Airbus has increased the service intervals for the aircraft from six years to 12, which significantly reduces maintenance costs for customers. The high percentage of composites also reduces the need for fatigue-related inspections required on more traditional aluminum jetliners, and lessens the requirement for corrosion-related maintenance checks.” On their company website. Boeing has also seen a significant savings on maintenance, particularly on the 777 where the composite tail is 25% larger, yet requires 35% fewer scheduled maintenance labor hours as a result of reduced risk of corrosion and fatigue of composites compared to metal. When considering the design from cradle to grave, a benefit such as this is very appealing to the design process, but overall is not included in the design requirements for this aircraft. Benefits in maintenance cost will not only lower the overall market price of the new aircraft being designed, but will also increase the overall lifespan of the aircraft. The use of advanced composites in structural components that typically see service for fatigue and corrosion repair ultimately leads to a more enduring vehicle. While the increased lifespan is not a design requirement, it certainly adds to the argument against composites: the cost. Certain composite materials can be extremely expensive, and often not worth the investment for the potential savings. The Wall Street Journal reported in 2013 that, “Robert Schafrik, general manager of materials and process engineering at GE Aviation, jokes that an advanced material is "one that costs 10 times as much as the current material." If that can be cut to just twice the price, he says, other savings in weight and maintenance costs can offset the difference.” Another issue adding to the cost of composites is the difficulty of production. As stated in the Boeing website magazine, “Boeing and its suppliers have also struggled with the Dreamliner's carbon-fiber and polymer structures. The plane's fuselage, for example, consists of barrels made from tape wound around cylindrical molds and then baked. Mastering the process was tough, and several of the first sections produced were rejected. In 2009, Boeing conceded it had to fix wrinkles in the skin of the first 23 barrels.” In making light of this, the team recognized that the actual determination of where and when advanced composite materials should be used is just as important as their actual implementation. Both Boeing and Airbus stress this when discussing these new materials, and also make light of the advancements in replacing aluminum with titanium and other new alloys. After conducting this trade study, it becomes clear that the best choice of material four our design is advanced composites. For the scope of this design project and provided the design parameters, it is quite obvious that a primarily advanced composite construction would be greatly beneficial in reducing the aircraft weight and ultimately reducing fuel burn. While the implementation of these materials may be costly, the design requirements do not stress cost as a restriction. Inherent concern obviously exists, but if the material placement is properly and carefully done, the design team feels that overall composites will significantly benefit in the design of an aircraft to replace the Boeing 757. 41 C. MATLAB Scripts Drag Build Up Calculations and Plotter %DRAG BUILD_UP %M-o-M TEAM 2 clear clc %Sea Level Velocity Points Vsl=[177 202 227 252 277 302 327 352 377 402 427 452 460 490 520 550]; %Cruise Alt. Velocity Points Vc=[427 452 477 502 527 552 577 602 627 652 677 702 727 752 777 802]; %A/C Parameters rho=.002378; rho2=.000738; qsl=0.5*rho*(Vsl.^2); qc=0.5*rho2*(Vc.^2); e=.98; AR=9; k=1/(pi()*e*AR); W_sl=281005; W_c=226758; S=2240; %========================================================================== %Induced drag============================================================== Cl_sl=W_sl./(qsl*S); Cdi_sl=(Cl_sl.^2)*k; Di_sl=qsl.*S.*Cdi_sl; Cl_c=W_c./(qc*S); Cdi_c=(Cl_c.^2)*k; Di_c=qc.*S.*Cdi_c; %========================================================================== %Profile drag============================================================== %XFOIL drag coeff's Cdp_sl=[.02438 .01145 .00899 .00768 .00692 .0068 .0068 .00669 .00666 .0066 .00653 .00656 .00647 .00643 .00638 .007]; Cdp_c=[.008 .008 .008 .008 .008 .008 .0082 .0084 .0089 .0093 .0099 .01 .0115 .012 .013 .014]; Dp_sl=0.5*(rho)*(Vsl.^2)*S.*Cdp_sl; Dp_c=0.5*(rho2)*(Vc.^2)*S.*Cdp_c; %========================================================================== %Fuselage drag============================================================= %X locations along fuselage X=[0.0000 6.5970 11.9503 18.9469 25.2194 126.3652 140.0341 154.7051 169.1080]; 42 Sf=6294.026059; %Total Surface Area of Fuselage msl=3.737e-7; mc=2.995e-7; %SEA LEVEL----------------------------------------------------------------Re_sl=zeros(9,16); i=1; j=1; for i=1:16 %Reynolds number based on X location for j=1:9 Re_sl(j,i)=(rho*Vsl(i)*X(j))/msl; end end Cf_sl=zeros(9,16); m=1; n=1; for m=1:16 %Coefficient of Friction for n=2:9 if (Re_sl(n,m) < 500000) Cf_sl(n,m)=1.328*(Re_sl(n,m)^(-0.5)); else Cf_sl(n,m)=0.455*((log(Re_sl(n,m))^(-2.58))); end end end Dfsl=zeros(1,16); y=1; for y=1:16 Dfsl(y)=qsl(y)*Sf*sum(Cf_sl(:,y)); %Sea Level Fuselage Drag end %CRUISE ALTITUDE----------------------------------------------------------Re_c=zeros(9,16); i=1; j=1; for i=1:16 %Reynolds Number based on X location for j=1:9 Re_c(j,i)=(rho2*Vc(i)*X(j))/mc; end 43 end Cf_c=zeros(9,16); m=1; n=1; for m=1:16 %Coefficient Friction for n=2:9 if (Re_c(n,m) < 500000) Cf_c(n,m)=1.328*(Re_c(n,m)^(-0.5)); else Cf_c(n,m)=0.455*((log(Re_c(n,m))^(-2.58))); end end end Dfc=zeros(1,16); %Cruise Fuselage Drag y=1; for y=1:16 Dfc(y)=qc(y)*Sf*sum(Cf_c(:,y)); end %========================================================================== %Trim drag ================================================================ %Tail Parameters St=561; ARt=4.5; et=0.97; lt=80.23; c_bar=18.11; x=4.2086-.25*c_bar; Clt_sl=(S/(St*lt))*(15*c_bar+x*Cl_sl); Clt_c=(S/(St*lt))*(15*c_bar+x*Cl_c); Cd_trim_sl=(St/S).*(Clt_sl./Cl_sl).*(((Clt_sl*e*AR)./(Cl_sl*et*ARt))2).*Cdi_sl; Cd_trim_c=(St/S).*(Clt_c./Cl_c).*(((Clt_c*e*AR)./(Cl_c*et*ARt))-2).*Cdi_c; Dtrim_sl=qsl.*Cd_trim_sl; Dtrim_c=qc.*Cd_trim_c; %========================================================================== %Tail drag ================================================================ Cdt_sl=Cdp_sl*St/S; Cdt_c=Cdp_c*St/S; Dt_sl=0.5*rho*(Vsl.^2).*Cdt_sl*St; Dt_c=0.5*rho2*(Vc.^2).*Cdt_c*St; %========================================================================== 44 %TOTAL DRAG =============================================================== Dtot_c=Dp_c+Dfc+Di_c+Dt_c+Dtrim_c; figure hold on plot(Vc,Dp_c,Vc,Dfc,Vc,Di_c,Vc,Dt_c,Vc,Dtrim_c,Vc,Dtot_c,'k'); title('Drag Build up: Cruise Altitude=35000 ft.') xlabel('Airspeed [Ft/s]'); ylabel('Drag Force [lbs.]'); legend('Profile','Fuselage','Induced','Tail Profile','Trim', 'Total','location', 'eastoutside') hold off Dtot_sl=Dp_sl+Dfsl+Di_sl+Dt_sl+Dtrim_sl; figure(2) hold on plot(Vsl,Dp_sl,Vsl,Dfsl,Vsl,Di_sl,Vsl,Dt_sl,Vsl,Dtrim_sl,Vsl,Dtot_sl,'k'); title('Drag Build up: Sea Level Altitude') xlabel('Airspeed [Ft/s]'); ylabel('Drag Force [lbs.]'); legend('Profile','Fuselage','Induced','Tail Profile','Trim','Total') hold off Engine Sizing Calculations and Constraint Diagram % Propulsion system sizing / constraint diagram % M-o-M Team 2 clear clc %% variables for thrust, weight, take off, and cruise parameters mu = 0.05; ws = [20:140]; sto = 7800; cdg = -0.3; cd0 = 0.018; clr = 0.325; rho = 0.002377; g = 32.174; w = 281005; s = 2213; rho_cr = 0.000738; e0 = 0.6; ar = 9; k = 1 / (pi*e0*ar); i = 0; j = 0; q = 0; vcr = 774.165333333; h = 42000; roc = 100/60; ldmax = 17; vst = 177.7838462; clmax = 2.82; 45 %% while loop to find the relation of the takeoff weight to the wing loading while i < 121 i = i +1; tw_num(i) = mu - ((mu+(cdg/clr))*(exp(0.6*rho*g*sto*cdg/ws(i)))); tw_den(i) = 1 - exp(0.6*rho*g*cdg*sto/ws(i)); tw(i) = tw_num(i)/tw_den(i); end %% while loop to relate the cruise thrust to weight to take off thrust to weight and wing loading sigma = rho / rho_cr; a = rho*cd0/2; b = (2*k) / (rho_cr*sigma); while j < 121 j = j+1; tw_cr(j) = (a*vcr^2/ws(j))+(b*ws(j)/vcr^2); end %% while loop to relate the service ceiling thrust to weight to take off thrust to weight and wing loading sigmac = 0.2967*exp(1.7355-(h*4.8075*(10^-5))); rho_sc = rho*sigmac; while q < 121 q = q+1; tw_sc1(q) = roc / (sigmac*sqrt(2*ws(q)*sqrt(k/cd0)/rho_sc)); tw_sc2(q) = 1 / (sigmac*ldmax); tw_sc(q) = tw_sc1(q) + tw_sc2(q); end ws_st = 0.5*rho*vst^2*clmax; tw_stall = linspace(0,1.4,100); ws_stall = linspace(ws_st,ws_st,100); plot(ws,tw,ws,tw_cr,ws,tw_sc,ws_stall,tw_stall) title('Constraint Diagram') xlabel('Wing Loading at Take off (W/S)') ylabel('Thrust to Weight Ratio at Take off (T/W)') legend('Takeoff','Cruise','Service Ceiling','Stall') 46