Development of a New Span-Morphing Wing Core Design

Abstract

This paper presents a new design for the core of a span-morphing unmanned aerial vehicle (UAV) wing that increases the spanwise length of the wing by fifty percent. The purpose of morphing the wingspan is to increase lift and fuel efficiency during extension, to increase maneuverability during contraction, and to add roll control capability through asymmetrical span morphing. The span morphing is continuous throughout the wing, which is comprised of multiple partitions. Three main components make up the structure of each partition: a zero Poisson’s ratio honeycomb substructure, telescoping carbon fiber spars and a linear actuator. The zero Poisson’s ratio honeycomb substructure is an assembly of rigid internal ribs and flexible chevrons. This innovative multi-part honeycomb design allows the ribs and chevrons to be 3D printed separately from different materials in order to offer different directional stiffness, and to accommodate design iterations and future maintenance. Because of its transverse rigidity and spanwise compliance, the design maintains the airfoil shape and the cross-sectional area during morphing. The telescoping carbon fiber spars interconnect to provide structural support throughout the wing while undergoing morphing. The wing model has been computationally analyzed, manufactured, assembled and experimentally tested.

Keywords

• airfoil
• 3D printing
• carbon fiber tubes
• telescoping spars
• chevrons