Design and cost analysis of integration of fluidic oscillator into a flap structure

Abstract

Integration of active flow control technology into civil transport aircraft is a highly desired objective due to the potential reductions in part count, weight, and recurring manufacturing costs. This study develops an optimal design for integrating a fluidic oscillator into the leading-edge of a trailing-edge flap structure on a civil transport aircraft. The design incorporates design specifications set by members of the aerospace industry, robust design methodologies, and simulation studies to create three separate designs that can be mass-produced. An analysis of the manufacturing, assembly, material, and weight reveals the cost of the design with respect to its production rate, which ranges from about $4090 per aircraft for low-production volumes to about $2600 per aircraft for high-production volumes. As a result, this study provides a basis for the design of manufacturing and assembly techniques to integrate active flow control technology into civil transport aircraft.

The design and manufacturing of fluidic oscillators for composite aircraft structures

“…Stereolithography printing (SLA) is limited to thermoset materials, and FDM has a higher surface roughness when compared to SLS; therefore, these two processes were not selected to manufacture the FOs. 5 Finally, costs were compared for parts using different combinations of processes to produce a low cost final product.…”

“…While these configurations provided feasible solutions for integrating the devices into the skin, they did not allow for serviceability as the attachment methods were permanent. A recent paper by Li and Colton 5 showed the attachment design of a FO into a composite wing-flap front bullnose. However, this design focused on attaching the FO to a non-structural, fiberglass part of a wing flap, where it will be more accessible for servicing rather than a structural region within a wing flap.…”

“…Prior research has used 3D printing techniques to create the FO’s small and complex geometries and to reduce overall part count. 4,5 Manufacturing methods for micro-FOs, which are similar to FOs, have also been studied. Research by Becker provided an overview of several methods including 3D printing, injection molding (IM), precision machining, and thermoforming, while research by Glenn provided estimates for FO manufacturing costs using different manufacturing methods at several batch quantities.…”

“…7,8 Thermoforming was once again found to be effective for small quantities, while IM and compression molding were effective for high part volumes in excess of 10,000 parts. Li and Colton 5 also conducted a cost analysis for three FO designs for a non-structural wing region. 3D printing was found to be useful for small part counts, while IM was more cost effective for part counts larger than 1000 parts.…”