Over the past decade, increasing use of continuous fiber-reinforced polymer composites has created a demand for manufacturing methods with lower costs, higher production rates, and improved processing efficiency. To meet the growing demands, vacuum bag only (VBO) prepreg processing has been proposed and implemented in industrial settings. However, in the absence of high consolidation pressure, VBO prepreg must undergo compaction for longer durations during cure and requires use of more elaborate processing schemes to conform to complex geometries. The main objective of our cure cycle modification was to reduce overall manufacturing time for more efficient processing, while maintaining robust part quality. This study demonstrates the effect of cure cycle on formability and part quality of three complex-shaped composite structures, a bulkhead, fuselage, and I section frame, featuring drop-offs, corners and sandwich areas consisting of less than 10 plies. Three different cure cycles were chosen: Reference cure cycle 1, Modified I and Modified II cure cycle. The reference was modified based on resin cure kinetics/viscosity modeling results and “effective flow number” to shorten the overall cure cycle time while maintaining robust part quality. To compare the quality of manufactured parts, destructive test and digestion method were used. For the bulkhead parts, Modified I was proven to be more effective in meeting the commercially acceptable part criteria (void content, ply wrinkle, resin ridge, and surface resin starvation), whereas Reference failed to meet the requirements, showing pervasive presence of porosity in drop-offs, corners and sandwich areas. The fuselage and I section frame parts produced with Modified I and Modified II were shown to meet the part quality requirements, with slight improvements in surface quality observed with the Modified II method.
This paper focuses on the hover performance experiment of a small-scale single rotor in partial ground conditions. In this study, small-scale rotor blade rotating device and floor panel are used to include partial ground effect. Thrust and torque were measured with varying collective pitch angles at fixed rotor rotating speed. The overlap distance between rotor and ground is d, the rotor diameter is D. It was shown that the ground effects have little effect on the rotor performance until d/D is 0.25. Four blade rotor has more increased thrust and more reduced power than those of two blade rotor because of stronger ground effect. In addition, it was also found that the thrust increases as a collective pitch angle become smaller. Based on these experiment results, we deduced new empirical equation considered blade number and partial ground effect.
This paper presents the work being carried out in order to deduce hover performance of a small-scale single rotor blade as a preliminary study of a small coaxial rotor helicopter development. As an initial research, a test stand capable of measuring thrust and torque of a small-scale rotor blade in hover state was constructed and fabricated. The test stand consists of three parts; a rotating device, a load measuring sensor and a data acquisition system. Thrust and torque were measured with varying collective pitch angle at fixed RPM. Through this research, hover performance tests were conducted for a small-scale single rotor blade operating in low Reynolds numbers (Re ≈ 3 × 10 5 ). The rotor blades investigated in this paper have maximum FM values varying from 0.59 to 0.65, which are low relative to modern full-scale helicopters. From these differences in FM between a small and a full-scale helicopter, the induced power factor is determined as varying from 1.35 to 1.42. Through this study, tests of hover performance were conducted for a single small-scale rotor blade, as well as verifying the test stand itself for the acquisition of hover performance.
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