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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - PRODIGE (PRediction of aerOdynamics and hinge moment loaDs at hIgh mach and fliGht rEynolds number)

Teaser

Summary

PRODIGE is designing the experimental setup of a cryogenic wind tunnel test campaign on a scale model of a business jet with the objective to generate accurate loads and hinge moment measurements. At this end, PRODIGE is designing and building a cryogenic 1/16 scale model of a business jet equipped with a hinge moment balance. This last one has been preliminarily designed, and is going to be tested and calibrated to work in cryogenic conditions. Successively, it will be integrated in the WT model and shall be used to generate experimental accurate loads and hinge moments at High Mach and flight Reynolds numbers.
The overall objective of PRODIGE is to support the development of methods to increase aerodynamic performance and efficiency, leading to positive ecological impact, less fuel consumption, thus less operating costs and more affordable flights, all resulting in a benefit for the society and in the enhancement of European industry competitiveness.

Work performed

WT model and test requirements have been extensively discussed with the TM during the first period: two different versions of the requirement document have been issued by Dassault Aviation (DASSAV).
A specific document, containing a detailed risk plan with related contingency measures has been prepared by IBK as part of the Management and Coordination tasks and then agreed and countersigned by DASSAV. The document has been shared with the JU as part of the closure evidences of the Milestone M7 (T0+6), â€œWT model Requirements Assessmentâ€, achieved on November the 30th.
The preliminary design of the model fuselage has been completed by IBK and will be part of the upcoming PDR.
The preliminary design of the wings have been mostly completed by IBK, the only open points at the end of the period in object, refer to the connection of the interchangeable ailerons to the aileron balance (fitting strategy) to ensure the absence of pressure tap leakage during the test campaign (the aileron is equipped with pressure taps).
CFD calculations to evaluate structural loads in the different WT conditions have been mostly completed by DREAM, CFD-CSM coupling analyses, to calculate loads by taking into account the structural flexibility, are ongoing. However, preliminary results showed that loads evaluated by considering the wing as a theoretically rigid structure are conservative, thus these loads are being used to perform the preliminary structural and stress analysis. Final CFD-CSM calculations performed in cooperation between DREAM and IBK will be eventually used to verify that the structure is safe even in case of structural elasticity effects taken into account.
The preliminary design of the local balance aimed at accurately measuring the aileron hinge moment has been completed in November 2019 (T0+9) by TUDA. However, many technical discussions between PRODIGE and the TM, focusing on design aspects related to balance features and balance-wing integration, led to a significant extension of the design review with the TM.
At the end of the period, different solutions involving wing-integral or aileron-integral balance arrangements are still under discussion. Technical advantages and disadvantages, together with risks concerning different design solutions are being evaluated with the aim to find an agreement with the TM on the best solution in terms of performance (measurement accuracy) and safety (risk level).
All the design and analysis activities, performed by IBK, DREAM and TUDA during the first period, gained benefit from the precious suggestions and manufacture feasibility analysis provided by DEHARDE.

Final results

the expected impact of PRODIGE lies within three major areas:
â€¢ Its impact on European competitiveness within the aeronautical arena;
â€¢ Society and Environment;
â€¢ A larger impact on innovation and knowledge integration.
The magnitude of the expected impact can be appreciated considering the envisaged, but realistic, advantages to improve aerodynamic efficiency of business jet aircraft in transonic conditions. These aspects have a reasonable impact in terms of direct and indirect costs, making the aircraft of new generation a competitive product because the correct prediction of the loads and hinge moment in transonic conditions will allow defining the right structure for the airplane, without weight excess.
Furthermore, PRODIGE is contributing to the reduction of certification costs by reducing wind tunnel testing and by developing new design approach strongly based on the data generated in this project. The project is supporting the WP A.1-4 AIRFRAME strategy devoted to enhance the adoption of virtual modelling in the design processes for certification purpose. In particular, the project will contribute to improve the loads and efficiency prediction of control surfaces at High Mach and flight Reynolds numbers.
Moreover, the PRODIGE project offers the opportunity to enlarge the area of interest to other Clean Sky IADP work programmes enabling technologies for other applications aiming to maximise the synergies between different aircraft configurations. Military, civil, fixed wing transports, short, medium, and long-range vehicles are just some examples of the wide spectrum of use of the Project outcomes within the aerospace sector.
A direct positive impact for the different partners is given by the exploitation. IBK has a strong motivation to continue increasing the visibility and competitiveness of their design capability by displaying their innovative methods and means as already showed in other domains such as REG (CS2), GRA and SFWA (CS) where the design of complex WT models (elastically scaled, dynamically scaled or powered models) has been performed. TUDA is increasing its recognition at European level as an excellent university partner capable of performing research but also of designing accurate complex hinge moment balances working in critical conditions (such as cryogenic and pressurised ones) successfully. DREAM is gaining more visibility providing support in the correct evaluation of the loads and hinge moment in a pilot-project that is recognized EU-wide. Finally, DEHARDE is an industrial partner that for the first time is involved in a research project funded by the European Commission. Although it has already a long tradition (more than 50 years) and an international recognition in the manufacturing of complex tailor-made wind tunnel models, built with highest precision and reliability able to work in every type of flow conditions, DEHARDE has decided to participate to the PRODIGE project by contributing with their knowhow to the improvement of the model manufacturing. This is extending their visibility from the industrial field to the applied research world.
Each partner involved in the project have the opportunity to further increase their know-how transferring the IPs generated in this project into own core business.
The coordinator of this project, IBK, together with DREAM and TUDA are also supporting universities by giving lectures. This impact goes beyond technical benefits/ impacts and produces social benefits by transferring knowledge to next generations of engineers.
Finally, as part of the Cleansky2 main program, the present project will help protect and develop highly skilled jobs within European aeronautics and its supply chain, including academia, ROs and SMEs; against a backdrop of significantly increased global competition.