Project Overview
The goal of this project is to design and analyse a high-performance rear wing that optimises downforce and aerodynamic efficiency within practical constraints. The selected primary airfoil for the mainplate is the NACA 633618, chosen for its favourable lift-to-drag characteristics.
Development Process
Product Selection and Implementation
To ensure an effective aerodynamic solution, I utilised:
- SolidWorks & STAR-CCM+ for CAD modelling and Computational Fluid Dynamics (CFD) simulations, while ANSYS was used for Finite Element Analysis (FEA).
- Wind tunnel testing equipment provided by the RS Fund to validate simulation results.
- High-performance composite materials to explore lightweight yet strong wing construction, with the potential for a scaled carbon model still being considered for further validation.
Throughout the development, multiple design iterations were conducted, modifying wing geometry, endplate design, and adjusting the angle of attack to achieve optimal aerodynamic performance.
Challenges and Solutions
One of the main challenges initially was learning CFD specifically for this project using STAR-CCM+, as I had never used it before. Understanding its application in industry and recognising its power as a CFD tool compared to ANSYS made it a valuable skill to develop. Through self-learning and hands-on application, I was able to harness its advanced capabilities for aerodynamic analysis.
Another significant issue encountered was flutter on the end plate at high speeds in the wind tunnel. Due to the curved design of the end plate, the bottom section, which could not be fixed in the wind tunnel setup, experienced substantial flutter, nearly leading to structural failure at approximately 30 m/s. This was largely due to the material constraints of 3D printing, as the part being tested was not yet manufactured in carbon fibre, with the design still undergoing refinement.
To mitigate this issue, I removed the bottom mounting flap of the wing, as it was only for mounting purposes and did not significantly impact aerodynamic performance. This adjustment successfully prevented structural failure in the wind tunnel and has been retained for all further design iterations. The variance in results due to this modification has been accounted for and justified through CFD analysis.
Additionally, high-fidelity 3D models were required for wind tunnel testing, necessitating multiple printed iterations. Due to the size and complexity of these models, a specialised 3D printer was needed to ensure the Reynolds number in wind tunnel testing remained consistent with the CFD simulations. The cost of these high-precision models was significant, but with the financial support from the RS Fund, I was able to produce multiple iterations to refine and validate the design effectively.
Results and Impact
The funding enabled me to validate my design with real-world testing, leading to the following key outcomes. Through this process, I gained deeper insights into how the positioning of multiple airfoils affects airflow, and how the angles of attack influence both downforce and drag. By experimenting with different setups in CFD and wind tunnel testing, I determined the optimal configuration to balance aerodynamic efficiency. This knowledge has been crucial in refining my design for improved performance.
- Improved aerodynamic efficiency: Achieved an optimised balance between downforce and drag reduction.
- Structural reliability: Implemented design modifications that successfully mitigated excessive elastic twist.
- Enhanced technical knowledge: The project provided valuable insights into aerodynamic design that will be beneficial for future engineering applications.
Conclusion
This project has been a transformative experience, bridging theoretical knowledge with practical application. The RS Fund played a crucial role in facilitating access to resources that would have otherwise been challenging to secure. I encourage fellow student engineers to pursue their own innovative projects and leverage available funding opportunities to turn their ideas into reality.
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