Kevin Nicholls, EIVW Prepared by Heinz Hansen TOP-LDA ... · filler cover . DLR . floating joint ....
Transcript of Kevin Nicholls, EIVW Prepared by Heinz Hansen TOP-LDA ... · filler cover . DLR . floating joint ....
NLF Slat on A320 Quick Technology Evaluation (Performance only)
Programme Discussions Kevin Nicholls, EIVW
Laminarität für zukünftige Verkehrsflugzeuge Überblick, Anforderungen und Status Ergebnisse des AirbusTechnologieprogramms Low Drag Aircraft (TOP-LDA)
Wissenschaftstag Braunschweig 2015 Prepared by Heinz Hansen
TOP-LDA Leader, ETEA Presented by Bernhard Schlipf, ESCRWG
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Content TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
2 Requirements and selected Approach
3 Structure Concepts Status
1 TOP LDA Introduction & Overview
4 Manufacturing and Flight Test Demonstration
5 Summary & Outlook
Page 2
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Content
2 Requirements and selected Approach
3 Structure Concepts Status
1 TOP LDA Introduction & Overview
4 Manufacturing and Flight Test Demonstration
5 Summary & Outlook
Page 3
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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0 $
1 $
2 $
3 $
4 $
5 $
Jan. 90 Jan. 94 Jan. 98 Jan. 02 Jan. 06 Jan. 10 Jan. 14
Page 4
Jet Fuel Price as Driver for Performance Improvement
Source: US Energy Information Administration, 9 November 2012
1990-2001 average 59 ct / gal
12 Sep 2008 4.81 $ / gal
First gulf war Second gulf war
11 Sep 2001
15 Sep 2008 Lehman Brothers
first major Airbus laminar R&T
activities
Jet fuel price
restart of Airbus laminar R&T activities
Drag reduction (by laminar flow) and efficient engines are key elements for reduction of fuel consumption
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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What is laminar flow?
V = 0 Aircraft surface
Schematic Representation of Boundary Layer Skin friction coefficient
Laminar flow can reduce friction drag significantly Friction drag contributes to total a/c drag with ≈ 50% Biggest contributor to friction drag is wing and fuselage Laminarisation of fuselage is very challenging A laminar wing upper side has a bigger effect than lower side (≈ 65%)
For a typical wing application a reduction of total drag in the order of up to 8% is possible by laminar flow on upper side
laminar turbulent
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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What are major influence factors for laminar flow?
Natural laminar flow (NLF): laminar boundary layer by wing airfoil shape only Hybrid laminar flow (HLF): active control (suction, cooling) of boundary layer & airfoil shaping Laminar flow influenced mainly by:
Wing pressure gradient (= airfoil shape) Reynolds number (= size, speed, altitude) Leading edge sweep (= Ma number)
Smoothness of wing surface (waviness, steps, gaps, roughness) Three dimensional disturbances (fasteners, insects, scratches, ...)
Aer
o
Stru
ctur
e
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Characteristics of laminar Airfoils Cp
x/c
laminar
turbulent
turbulent
laminar
• accelerated flow needed to get large extent of laminar flow • this has a negative effect on shock strength (especially at high Ma) • wing box of laminar wing similar to turbulent but more volume aft • leading edge: sharp, less space front spar more aft
thick & round leading edge
• narrow & sharp leading edge • front spar moved back
• max thickness far aft • increased rear spar height
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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How Hybrid Laminar Flow works
SUCTION SHAPING
Hybrid Laminar Flow Control (HLFC) required at high sweep of leading edge (LE) and high Reynolds number Can be reached by:
• Optimized aerodynamic shape of the airfoil and • Small suction at the leading edge for stabilization of boundary layer • Tight control of the manufactured shapes to remove perturbations at the skin, and
A320 VTP Flight Test with suction 1998
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Content
2 Requirements and selected Approach
3 Structure Concepts Status
1 TOP LDA Introduction & Overview
4 Manufacturing and Flight Test Demonstration
5 Summary & Outlook
Page 9
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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What is different in comparison to the past?
20% 40% 30% 50%
F100 NLF Glove 1992 ATTAS NLF Glove 1987 A340 HLFC Glove A320 HLFC Fin
Past: Aerodynamic basic research with glove technology and hand finishing of surface
Today: Realistic structure concept fulfilling aerodynamic requirements and manu- facturing at acceptable cost; demonstration of concepts on ground and in FT
Robust aero design
Specific wind tunnel
test
NLF wing
BLADE Flight Test
Large NLF wing LE ground demonstrator
Joint concepts
Manufacturing trials
Saab
DLR
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Surface Requirements: Experimental approach
TSP coating Adjustable leading edge step
2D Step testing
2D Waviness in LE + Step
3D Waviness + Multiple Waves
Realistic Structure Simulation
Xtr m
ovem
ent
Surface imperfection increase
Limit?
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CFD Validation for Surface Requirements
∆Z enlarged
3D Navier-Stokes including WTT wall effects
Experiment in KRG Ma=.75 Cl=design
Re=13Mio
3D CFD Result
temperature distribution
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Surface quality measurements
flaps measurements before & after assembly
MBF (Composite Structure)
Stringer Position
inboard outboard
Manufacturing Waviness is strongly dependent on build concept (stringer spring in, etc.)
Wing box example Flap box example
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Content
2 Requirements and selected Approach
3 Structure Concepts Status
1 TOP LDA Introduction & Overview
4 Manufacturing and Flight Test Demonstration
5 Summary & Outlook
Page 14
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Page 15
NLF Wing Structure Overview • Box
• Minimal change to turbulent box configuration • Lower Skin, Rear Spar and lower flange of Front Spar construction unchanged • Upper Skin certification challenges for “no fastener” joints and integral front spar cap
• Leading Edge • Change to LE design key to meeting NLF requirements • Joint to box critical, challenging build requirements and life management • Slats replaced by Krüger-Flaps
• which provide both high lift and bug protection • Electric WIPS introduced
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Krüger High-lift and Shielding Concept and Testing
Krueger shielding
Definition of acceptable values for Krueger setting Constraints for structure and kinematics concept
Kinematics Validation Coating Studies 125° Krueger
Numerical &
Experimental Validation
Page 16
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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NLF Leading Edge Skin sub assembly
Deployed Krüger
Stowed Krüger
Page 17
Leading edge with high lift installation
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
electricalWIPS
Thermoplastic sheet
Erosion shield
Sub-structure
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Page 18
Examples of Joint and Fastener Head Options
AGI filler cover
DLR floating joint
The joint area and the filler
application is a very critical zone
for a laminar wing structure
concept
Several partners are working
on that topic and
flight demonstration in BLADE
is planned as well
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Content
2 Requirements and selected Approach
3 Structure Concepts Status
1 TOP LDA Introduction & Overview
4 Manufacturing and Flight Test Demonstration
5 Summary & Outlook
Page 19
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Page 20
Ground Based Demonstrators in context of TOP-LDA
DLR CFRP LE concept
floating joint
GKN CFRP LE concept
machined joint
Krueger Test rigs BLADE demonstrators
Saab GKN
& machined metal LE
Airbus metal LE concept
metal LE self supported
Ground Based Demonstrator in SFWA
4.5m span NLF leading Edge
Check several approaches and select the best mix out of the different demonstrators
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Page 21
Upper Cover DLR NLF Manufacturing Demo
Major Objectives: Development of new CFRP wing cover structure concept and manufacturing demonstration for laminar wing application
wing cover tooling
LaWiPro
Stade 13.6.2013
Surface
quality
analysis
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Page 22
GKN Ground based NLF LE Demonstrator
Ground based NLF leading edge demonstrator including Krueger and WIPS integration 4.5m length
Major Objectives:
Demonstration of full LE integration of all NLF leading edge components and manufacturing and assembly quality of large leading edge parts
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Page 23
BLADE A340 MSN1 Flight Demonstration
Major Objectives: • Design and manufacturing of NLF
outer wing • Flight testing of NLF wing with
two different structure concepts • Demonstration and validation of
aero design and CFD tools • Validation that selected structure
concepts are feasible and deliver expected surface quality
• Testing of artificial disturbances and operation simulation
• Testing of Kruegershielding
joint
Leading edge with joint to box GKN
Continuous surface Saab
A340-300
Representation of laminar wing on A340 flying test bed
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Content
2 Requirements and selected Approach
3 Structure Concepts Status
1 TOP LDA Introduction & Overview
4 Manufacturing and Flight Test Demonstration
5 Summary & Outlook
Page 24
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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Page 25
Summary and Outlook
• Surface quality is a major challenge for laminar flow application and detailed knowledge about surface requirements is needed to find best compromise between structure solution and aero performance
• CFD capabilities further improved and validated to predict such effects
• Small, medium size and full wing demonstrators and validation experiments including large scale flight test with A340MSN1 will be used to get confidence in what is possible
• Specific wind tunnel test have been designed to get such precise requirements
• There are several activities with different partners running to find the best structure and manufacturing concept for the leading edge and upper cover of a laminar wing
• Operability of such laminar wings and surface quality degradation effects will be an additional important topic in the future
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015
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What will come next?
Page 26
Flight test with simplified HLFC on the VTP
of the A320 DLR ATRA aircraft in 2017
Wing LE HLFC Ground Demonstrator
HLFC system
SAAB
GKN
AERNNOVA
Manufacturing of BLADE large FT demonstrator
Final assembly
Flight test with NLF outboard wings on A340
BLADE demonstrator end of 2017
TOP-LDA Vortrag Wissenschaftstag Braunschweig 7. Oktober 2015