Browse Topic: CAD, CAM, and CAE
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This paper discusses the design of a 2000-lb manned eVTOL aircraft propelled by a novel cycloidal rotor propulsion system. To systematically evaluate the performance of the proposed configuration, a coupled trim model was developed to quantitatively evaluate the performance of the configuration across a range of forward flight speeds. The trim framework integrates an efficient physics-guided neural-network-based aerodynamic model for cycloidal rotor performance with a vehicle-level dynamic response model. This framework is used to conduct a systematic parametric study to identify key cycloidal rotor and airframe design parameters. The selected configuration is verified using high-fidelity CFD simulations, and a detailed structural design, powertrain design, and CAD model of the aircraft is developed. In addition to CFD validation, the proposed cycloidal rotor underwent structural optimization to confirm the validity of such a concept at this scale. The results demonstrate that the cycloidal rotors provide a viable propulsion alternative for eVTOL aircraft with strong potential to overcome limitations of existing configurations.
Accurate simulation of fluid-structure interactions (FSI) is critical for designing aircraft systems, particularly for applications involving fuel tank sloshing and large deformations. Traditional added mass methods often fail to capture the nonlinear and frequency-dependent behavior of these coupled systems. This study applies the Finite Pointset Method (FPM), a mesh-free computational fluid dynamics (CFD) technique, coupled with an explicit finite element solver, to predict complex FSI phenomena. Validation is performed using benchmark experiments, including a harmonic tank sloshing test and a guided plate ditching scenario, with results demonstrating strong agreement with measured pressures and structural responses. Additional validation on a composite fuel tank drop impact test confirms FPM's ability to model large deformations and rupture under dynamic loading. The findings highlight FPM's robustness and adaptability for aerospace FSI problems, offering a powerful alternative for virtual prototyping and certification workflows where conventional methods are insufficient.
This paper introduces a Multidisciplinary Design and Optimization (MDO) approach for the design of a tiltrotor wing, utilizing as test case a semi-wing with integrated nacelle and rotor. Structural integrity is assessed via stress analysis on a GFEM, which also forms the basis for a coupled wing-rotor aeroelastic model to ensure whirlflutter stability. Aerodynamic performance is assessed through CFD analysis of two-dimensional wing's airfoil shape. The MDO workflow leverages three levels of design space control that can influence the structural response of the wing: other than controlling the structural properties of composite materials, the internal wing-box architecture and external airfoil shape are modified acting directly on the FEM by means of a mesh morphing technique. This methodology allows for the use of mid-fidelity finite element models, bypassing CAD reshaping and remeshing. Validation tests confirm the approach's effectiveness in producing optimized designs. Additionally, the study explores surrogate models as efficient alternatives to CFD simulations, yielding sufficiently accurate results while reducing computational costs and the MDO simulation time.
An essential component for the advancement of autonomous flight lies in the development of an intelligent routing system designed to facilitate the maintenance and troubleshooting of electrical wiring. Utilizing software with the capability to present routed paths in a computer-aided design (CAD) format allows for a detailed representation of the rules governing the layout of wiring around structural supports and distribution channels. Despite this, three-dimensional (3D) methodologies have yet to fully incorporate critical data related to the characterization of individual wiring signals, hindering automatic routing. This paper underscores a competitive edge that can be achieved by expanding 3D capabilities to accurately depict the current state of wiring signals in terms of temperature, humidity, electromagnetic frequency, amperage, and other relevant factors. Achieving this involves integrating a non-intrusive smart sensing technology with the intelligent routing system to monitor and diagnose the health and integrity of the wiring system. With this integration, a more robust artificial intelligence (AI) system can leverage the obtained data to make more precise decisions, enhancing overall system performance.
Fundamental advancements in aircraft design over the past 50 years have enabled a range of Vertical Takeoff and Landing (VTOL) air vehicle configurations and have significantly enhanced aircraft performance, safety, and reliability. This summary paper chronicles the evolution of rotorcraft design from 1974-2024 as presented by the Vertical Flight Society (VFS) Aircraft Design Technical Committee (TC). It is segregated into three key pillars of aircraft design preceded by an aircraft design overview. The three pillars are: processes and tools, technology, and air vehicle configuration. The first pillar on design processes and tools describes advancements in technology, methodologies, and computational capabilities such as the transition from design solely by wind tunnel testing, physical models, and hand calculations to computer aided design/synthesis and simulation in a model-based engineering digital-twin environment. The second pillar on technology focuses on advances in disciplinary technologies and how they have been incorporated into aircraft design. Technologies discussed include composite materials; rotor systems; propulsion systems, ranging from advancements in turbine engines to all- and more-electric propulsion technologies utilizing various energy storage systems to convertible engines; fly-by-wire systems; avionics and cockpit architectures, including digital displays, navigation aids, and communication equipment; and autonomous and semi-autonomous systems. The third pillar on air vehicle configuration focuses on platform architectures. Major architectures discussed are high-speed VTOLs such as the thrust-vectored aircraft, tiltrotors, lift/thrust compounded helicopters and all- and more-electric aircraft.
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