Rea, Francesco (2018) Preliminary and advanced structural design of a three-modal camber morphing wing flap for large civil aircraft applications. [Tesi di dottorato]

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Researchers and engineers design modern aircraft wings to reach high levels of efficiency with the main outcome of weight saving and airplane lift-to-drag ratio increasing. Future commercial aircraft need to be mission-adaptive to improve their operational efficiency. Within the framework of Clean Sky 2 Airgreen 2 (REG-IADP) European research project, a novel multifunctional morphing flap technology was investigated to improve the aerodynamic performances of the next Turboprop regional aircraft (90 passengers) along its flight mission. The proposed true-scale device (5 meters span with a mean chord of 0.6 meters) is conceived to replace and enhance conventional Fowler flap with new functionalities. Three different functions were enabled: overall airfoil camber morphing up to +28 deg (mode 1), +/- 10 deg (upwards/downwards) deflections of the flap tip segment (mode 2), flap tip twist of +/- 5 deg along the outer flap span (mode 3). Morphing mode 1 is supposed to be activated during take-off and landing only to enhance aircraft high-lift performances and steeper initial climb and descent. Thanks to this function, more airfoil shapes are available at each flap setting and therefore a dramatic simplification of the flap deployment system may be implemented. Morphing modes 2 and 3 are enabled in cruise and off-design flight conditions to improve wing aerodynamic efficiency. The proposed structural concept consists of a multi-box arrangement activated by segmented ribs with embedded inner mechanisms to realize the transition from the baseline configuration to different target aero-shapes while withstanding the aerodynamic loads. Lightweight and compact actuating leverages driven by electromechanical motors were properly integrated to comply with demanding requirements for real aircraft implementation: minimum actuating torque, minimum number of motors, reduced weight, and available design space. The methodology for the design of the inner mechanisms is based on a building block approach where the instant centres analysis tool is used to preliminary select the locations of the hinges’ leverages. The structural layout of an Adaptive Twist composite Tab was considered as a promising concept to balance the conflicting requirements between load-carrying capability and shape adaptivity in morphing lightweight structures. Finally, the embedded system functionality of the actuation system coupled with the structural skeleton is fully investigated by means of detailed finite element simulations. Results of actuation system performances, and aeroelastic deformations considering limit aerodynamic loads demonstrate the potential of the proposed structural concepts to be energy efficient, and lightweight for real aircraft implementation.

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