2. Heavy Lift Cargo Plane Proposal Matthew Chin, Aaron Dickerson, Brett J. Ulrich, Tzvee Wood October 5 th, 2004 Group #1 – Project #3

3. Project Introduction The apex of design courses, work will focus on applying course knowledge to an industrial project The apex of design courses, work will focus on applying course knowledge to an industrial project Project will encompass planning, design, construction and testing of a complete engineering endeavor Project will encompass planning, design, construction and testing of a complete engineering endeavor Teamwork and leadership skills will be an important factor in the synthesis of a complete design Teamwork and leadership skills will be an important factor in the synthesis of a complete design Learn / Experience design process first hand from design to construction to testing Learn / Experience design process first hand from design to construction to testing

4. Background Need for heavy lift cargo planes to serve energy/mining/military sectors Need for heavy lift cargo planes to serve energy/mining/military sectors Short takeoff and landing (STOL) Short takeoff and landing (STOL) Fuel efficiency for long range transport Fuel efficiency for long range transport Current market limited - Ukrainian-built Antonov only real contender - Antonov An- 225 capable of transporting over 250 tons – only one built Current market limited - Ukrainian-built Antonov only real contender - Antonov An- 225 capable of transporting over 250 tons – only one built An-124 – 150 ton payload capacity An-124 – 150 ton payload capacity

5. Project Impact Change air transport options Change air transport options Enhance ability to distribute natural resources Enhance ability to distribute natural resources Reduce shipping costs, time, and energy consumption Reduce shipping costs, time, and energy consumption Broader military transport options Broader military transport options

6. Project Objectives Compete in SAE Aero East Competition to design a heavy lift cargo plane Compete in SAE Aero East Competition to design a heavy lift cargo plane Apply areas of Mechanical Engineering education to a real life problem: Apply areas of Mechanical Engineering education to a real life problem: –Dynamics –Fluid Mechanics –Modeling & Simulation –Analysis of Stresses

7. Competition Selection Regular Class: Regular Class: –Maximum wing span –One type of engine, no modifications allowed Open Class: Open Class: –No wing span restriction –Any reciprocating internal combustion engine allowed –Maximum empty weight Micro Class: Micro Class: –No wing span restriction or weight limit –Internal combustion or electrical engines allowed –Winner determined by highest lift/weight ratio

8. Competition Selection Open and Micro Class require more in-depth design Open and Micro Class require more in-depth design –Selection of engine & fuel –Gearbox ratios different from 1:1 –Gyroscopic assist allowed Regular Class requires less design decisions Regular Class requires less design decisions –Concentrate on Airfoil & Body Design –Able to compete better with schools that focus on aerospace engineering –Stevens has previously entered Regular Class

9. 2005 Regular Class Requirements No lighter-than-air or rotary wing aircraft No lighter-than-air or rotary wing aircraft Maximum wing span of 60 inches Maximum wing span of 60 inches Take off zone of 200 feet Take off zone of 200 feet Landing zone of 400 feet Landing zone of 400 feet Single, unmodified O.S..61FX Engine with E-4010 Muffler Single, unmodified O.S..61FX Engine with E-4010 Muffler Payload bay must enclose a block measuring 5 in. x 6 in. x 8 in. Payload bay must enclose a block measuring 5 in. x 6 in. x 8 in. Plane that lifts the most wins Plane that lifts the most wins

10. 2005 Regular Class Requirements Cannot simply refine the 2004 entry Cannot simply refine the 2004 entry Requirements vastly different in 2004: Requirements vastly different in 2004: –10 ft. wing span minimum –6 in. x 5 in. x 4 in. payload bay Some components can be re-used to reduce cost: Some components can be re-used to reduce cost: –Engine requirement is the same from 2004 –Functioning servos can be reused

11. Anticipated Hurdles No group members have any previous aerospace engineering experience No group members have any previous aerospace engineering experience Rule changes have forced the team to conceive a totally different design from previous teams Rule changes have forced the team to conceive a totally different design from previous teams Construction irregularities must be minimized to produce results expected from theoretical design Construction irregularities must be minimized to produce results expected from theoretical design

12. Overcoming the Hurdles Consultation with project advisor and past competition participants will give insight into aerospace design process Consultation with project advisor and past competition participants will give insight into aerospace design process –Existing research links –Techniques for design and building WINFOIL software will be employed in aircraft design WINFOIL software will be employed in aircraft design –Enables trial and error approach to augment theoretical calculations –Design can be exported to CAD –CAD drawings can be used with CNC machinery

13. Preliminary Concepts Flying wing Flying wing –Fuselage is built into wing, cuts down on air resistance –Reduces material required for fuselage –May be difficult to support/brace payload bay properly Biplane Biplane –Larger wing surface area –Increase in lift –Not enough engine power supplied

14. Preliminary Concepts Monoplane Monoplane –Clear and distinct parts –Easy to build –High lift when right wing is chosen –Large quantity of known data –Rather “simple” calculations Team selected Monoplane for design Team selected Monoplane for design

15. Preliminary Concepts

16. Conceptual Designs Limited conceptual designs available at this time: Limited conceptual designs available at this time: –No group member has previous aeronautical engineering or RC plane design experience –Competition requirements have only been available since the end of September WINFOIL Software will be used in developing wing and fuselage design WINFOIL Software will be used in developing wing and fuselage design

17. Project Needs/Metrics

20. Heavy Lift Considerations High lift versus Wing weight/Stability High lift versus Wing weight/Stability  Material  Number of Ribbing  Thickness of Wing  Lesson Learned from last year  Flaps Max lift for area Max lift for area  Angle of wing  Aspect Ratio  Actual Type of Wing (ex. NACA 6409)  Type of Plane (ex. Monoplane)

21. Preliminary WINFOIL Trial

22. 3D Airfoil

23. Future Planes: The Technology Entire planes tested and designed on the computer Entire planes tested and designed on the computer  Wings  Tail Fins  Fuselage No tedious calculations No tedious calculations No human errors No human errors Easy inputs Easy inputs Pretty graphs and easily interpretable results Pretty graphs and easily interpretable results All plane data incorporated into program All plane data incorporated into program

24. Sample Calculations

25. Gantt Chart

26. Work Breakdown Schedule

27. Phase I: Design Budget Design budget does not include construction or competition costs Design budget does not include construction or competition costs Employee Cost: Employee Cost: –Wage: $30/hr (10 hrs per week, 14.5 weeks) –Benefits estimated at 50% wages: $15/hr –Total Phase I Employee Cost: $26,100 Additional funds required to cover overhead estimated at approximately 50% of total labor cost: $13,050 Additional funds required to cover overhead estimated at approximately 50% of total labor cost: $13,050 Total estimated Phase I Budget: $39,150 Total estimated Phase I Budget: $39,150

28. Future Deliverables Conceptual design sketches Conceptual design sketches Final calculations Final calculations Metrics used in airfoil selection Metrics used in airfoil selection Final plane design selection Final plane design selection Model of final design Model of final design Phase II: Construction Budget Phase II: Construction Budget

29. Conclusions Design requirements dictate the concentration on airfoil and fuselage design Design requirements dictate the concentration on airfoil and fuselage design Utilization of WINFOIL will enable the design team to overcome any theoretical inadequacies among team members Utilization of WINFOIL will enable the design team to overcome any theoretical inadequacies among team members Large scope of project dictates strict adherence to the proposed GANTT Chart Large scope of project dictates strict adherence to the proposed GANTT Chart

30. Feedback is Appreciated Thank You

31. References http://airfieldmodels.com/information_source/index.htm http://airfieldmodels.com/information_source/index.htm http://web.umr.edu/~aavg/ http://web.umr.edu/~aavg/ http://airfieldmodels.com/information_source/math_and_science_of_ model_aircraft/flaperons_on_model_aircraft.htm http://airfieldmodels.com/information_source/math_and_science_of_ model_aircraft/flaperons_on_model_aircraft.htm http://www.winfoil.com/ http://www.winfoil.com/ http://www.ctaz.com/~kelcomp/airfoils5.htm http://www.ctaz.com/~kelcomp/airfoils5.htm http://www.pdas.com/index.htm http://www.pdas.com/index.htm http://www.centennialofflight.gov/essay/Theories_of_Flight/airplane/ TH2.htm http://www.centennialofflight.gov/essay/Theories_of_Flight/airplane/ TH2.htm http://www.towerhobbies.com/rcwairinfo.html http://www.towerhobbies.com/rcwairinfo.html http://www.easyrc.com/airplanes/airplanes3.html http://www.easyrc.com/airplanes/airplanes3.html http://students.sae.org/competitions/aerodesign/east/ http://students.sae.org/competitions/aerodesign/east/