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Sandwich structures have been used in the aerospace industry for many years. The high strength to weight ratios that are possible with sandwich constructions makes them desirable for airframe applications. While sandwich structures are effective at handling distributed loads such as aerodynamic forces, they are prone to damage from concentrated loads at joints or due to impact. This is due to the relatively thin face-sheets and soft core materials typically found in sandwich structures. Carleton University's Uninhabited Aerial Vehicle (UAV) Project Team has designed and manufactured a UAV (GeoSurv II Prototype) which features an all composite sandwich structure fuselage structure. The purpose of the aircraft is to conduct geomagnetic surveys. The GeoSurv II Prototype serves as the test bed for many areas of research in advancing UAV technologies. Those areas of research include: low cost composite materials manufacturing, geomagnetic data acquisition, obstacle detection, autonomous operations and magnetic signature control.In this thesis work a methodology for designing and manufacturing inserts for foam-core sandwich structures was developed. The results of this research work enables a designer wishing to design a foam-core sandwich airframe structure, a means of quickly manufacturing optimized inserts for the safe introduction of discrete loads into the airframe.The previous GeoSurv II Prototype insert designs (v.l & v.2) were performance tested to establish a benchmark with which to compare future insert designs. Several iii designs and materials were considered for the new v.3 inserts. A plug and sleeve design was selected, due to its ability to effectively transfer the required loads to the sandwich structure. The insert material was chosen to be epoxy, reinforced with chopped carbon fibre. This material was chosen for its combination of strength, low mass and also compatibility with the face-sheet material. The v.3 insert assembly is 60% lighter than the previous insert designs.A casting process for manufacturing the v.3 inserts was developed. The developed casting process, when producing more than 13 inserts, becomes more economical than machining.An exploratory study was conducted looking at the effects of dynamic loading on the v.3 insert performance. The results of this study highlighted areas for improving dynamic testing of foam-core sandwich structure inserts.Correlations were developed relating design variables such as face-sheet thickness and insert diameter to a failure load for different load cases. This was done through simulations using Computer Aided Engineering (CAE) software, and experimental testing. The resulting correlations were integrated into a computer program which outputs the required insert dimensions given a set of design parameters, and load values.
Sandwich structures have been used in the aerospace industry for many years. The high strength to weight ratios that are possible with sandwich constructions makes them desirable for airframe applications. While sandwich structures are effective at handling distributed loads such as aerodynamic forces, they are prone to damage from concentrated loads at joints or due to impact. This is due to the relatively thin face-sheets and soft core materials typically found in sandwich structures. Carleton University's Uninhabited Aerial Vehicle (UAV) Project Team has designed and manufactured a UAV (GeoSurv II Prototype) which features an all composite sandwich structure fuselage structure. The purpose of the aircraft is to conduct geomagnetic surveys. The GeoSurv II Prototype serves as the test bed for many areas of research in advancing UAV technologies. Those areas of research include: low cost composite materials manufacturing, geomagnetic data acquisition, obstacle detection, autonomous operations and magnetic signature control.In this thesis work a methodology for designing and manufacturing inserts for foam-core sandwich structures was developed. The results of this research work enables a designer wishing to design a foam-core sandwich airframe structure, a means of quickly manufacturing optimized inserts for the safe introduction of discrete loads into the airframe.The previous GeoSurv II Prototype insert designs (v.l & v.2) were performance tested to establish a benchmark with which to compare future insert designs. Several iii designs and materials were considered for the new v.3 inserts. A plug and sleeve design was selected, due to its ability to effectively transfer the required loads to the sandwich structure. The insert material was chosen to be epoxy, reinforced with chopped carbon fibre. This material was chosen for its combination of strength, low mass and also compatibility with the face-sheet material. The v.3 insert assembly is 60% lighter than the previous insert designs.A casting process for manufacturing the v.3 inserts was developed. The developed casting process, when producing more than 13 inserts, becomes more economical than machining.An exploratory study was conducted looking at the effects of dynamic loading on the v.3 insert performance. The results of this study highlighted areas for improving dynamic testing of foam-core sandwich structure inserts.Correlations were developed relating design variables such as face-sheet thickness and insert diameter to a failure load for different load cases. This was done through simulations using Computer Aided Engineering (CAE) software, and experimental testing. The resulting correlations were integrated into a computer program which outputs the required insert dimensions given a set of design parameters, and load values.
Carleton University and Sander Geophysics are developing an unmanned aircraft system (UAS) for aeromagnetic surveying. As an early indication of the expected performance of the unmanned aircraft system, a simulated unmanned aircraft system (sUAS) was built. The simulated unmanned aircraft system is a T‐shaped structure configured as a horizontal gradiometer with two cesium magnetometers spaced 4.67 m apart, which is the same sensor geometry as planned for the unmanned aircraft system. The simulated unmanned aircraft system is flown suspended beneath a helicopter. An 8.5 km2 area in the Central Metasedimentary Belt of the Grenville Province, near Plevna, Ontario, Canada, was surveyed with the simulated unmanned aircraft system suspended 50 m above ground. The survey site was chosen on the basis of its complex geological structure. The total magnetic intensity (TMI) data recorded were compared to that obtained during a conventional fixed‐wing survey and a ground survey. Transverse magneto‐gradiometric data were also recorded by the simulated unmanned aircraft system. The simulated unmanned aircraft system total magnetic intensity data have a higher resolution than the conventional fixed‐wing data and were found to have a similar resolution to that of the ground survey data. The advantages of surveying with the simulated unmanned aircraft system were: (1) the acquisition of a detailed data set free of gaps in coverage at a low altitude above the terrain and (2) substantial saving of time and effort. In the survey site, the 4.67 m simulated unmanned aircraft system gradiometer measured the transverse magnetic gradient reliably up to an altitude of 150 m above ground.
Carleton University and Sander Geophysics are developing an unmanned aircraft system (UAS) with technologies to create a platform uniquely suited for aeromagnetic surveying. As an early indication of the expected performance of the UAS, a simulated UAS (sUAS) was built. The sUAS is a helicopter suspended T-shaped structure built with the same sensors and the same configuration as the UAS.An 8.5 km area near Plevna, Ontario, was surveyed with the sUAS suspended 50 m above ground. The survey area was chosen on the basis of its complex geological structure. The total magnetic intensity (TMI) data recorded was compared to that obtained during a conventional fixed-wing survey and a ground survey. Data from an experimental transverse magneto-gradiometer was also recorded by the sUAS and analyzed.
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