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Staff of Douglas Aircraft Company NASA CR 3704 NASA Contractor Report 3 704 C.1 DC- 10 Winglet Flight Evaluation StaffofDouglas Aircraft Company CONTRACT NAS I-1 5 3 2 7 JUNE 1983 25th Anniversary 1958-1983 TECH LIERARY KAFB, NM IlnllIlllInlIIl~llIIl~~Illlllll OOb233i’ NASA Contractor Report 3 704 DC- 10 Winglet Flight Evaluation StaffofDouglas Aircraft Company McDonnell Douglas Corporation Long Beach, California Prepared for Langley Research Center under Contract NAS 1 - 15 3 2 7 National Aeronautics and Space Administration Scientific and Technical Information Branch 1983 FilREWORD This document is the final report of the DC-10 Winglet Flight Evaluation, which was con- ducted as one task of Contract NASl-15327 under the NASA Energy Efficient Transport (EET) project. The evaluation program also contained Douglas-sponsored work. The NASA Technical Monitor for this contract was Mr. T. G. Gainer of Langley Research Center. The on-site NASA representative was Mr. J. R. Tulinius. Acknowledgment is also given to the Director and staff of the Dryden Flight Test Center for their assistance during the program. The work was conducted by Douglas Aircraft Company, Long Beach, at its facilities at Long Beach and Yuma, and at Edwards Air Force Base. The key personnel were: M. Klotzsche Aircraft Energy Efficiency (ACEE) Program Manager A. B. Taylor EET Project Manager P. T. Sumida Task Manager (also Detail Design subtask) W. H. Perks Manufacturing subtask W. B. Jones Aircraft Preparation subtask C. H. Fritz Laboratory Test subtask V. A. Clare Flight Test subtask D. J. Thomas Loads Measurement Program J. T. Callaghan Aerodynamics J. E. Donelson Aerodynamics The principal authors of this report were: J. R. Agar E. G. Salamacha J. T. Callaghan C. A. Shollenberger J. E. Donelson P. T. Sumida C. A. Felton A. B. Taylor F. S. Heiberger D. J. Thomas J. W. Humphreys . III SUMMARY This report presents the results of a flight evaluation of winglets on a DC-10 Series 10 transport aircraft. The objectives of the program were to determine the effects of winglets on aerodynamic performance and flying qualities by back-to-back tests with and without winglets, to determine flutter-related data, and to determine the effect of winglets on flight loads. The program consisted of detail design, winglet manufacture, aircraft preparation (includ- ing modification of the wing structure and installation of the winglets), and ground and flight testing. The basic winglet configuration used initially in the tests was directly related to the designs developed by Dr. R. T. Whitcomb of NASA Langley. These had a large upper winglet with a small lower winglet. A truncated version of the upper winglet was also tested to evaluate the effect of reducing the span. During the initial flight tests of the basic winglet, low-speed buffet was encountered. To resolve this problem, a number of configurations were developed and tested, several of which achieved acceptable low-speed buffet characteristics. The greatest low-speed-drag reduction was achieved using leading edge devices on the upper and lower winglets. Lower winglets were required for maximum drag reduction in both cruise and low-speed flight regimes. The addition of outboard aileron droop to the reduced-span winglet configuration enhanced the cruise benefit of winglets. It was found during the flight tests that winglets had no significant impact on stall speeds, high-speed buffet boundaries, or stability and control characteristics. The flutter tests did not reveal any unforeseen behavior, as the test results agreed with the analytical predictions and ground vibration data. Data from the loads measurement program, which were provided for a concurrent Douglas task, were also in agreement with predictions. It was estimated from the test results that the application of the reduced-span winglet and aileron droop to a production version of the current DC-10 Series 10 aircraft would yield a 3-percent reduction in fuel burned at the range for capacity loads of passengers and baggage, a 2-percent greater range at this payload, and a 5-percent reduction in takeoff distance at maxi- mum takeoff weight. V CONTENTS Section Page INTRODUCTION . 1 SYMBOLS . 7 PROGRAMSUMMARY . 15 WINGLET INSTALLATION DESIGN AND ANALYSIS ........................... 17 Winglet Configuration ..................................................... 17 Structural Design Criteria .................................................. 21 PredictionofFlightLoads .................................................. 23 Structural Description ..................................................... 24 StressAnalysis ........................................................... 27 FlutterAnalysis .......................................................... 27 WINGLETMANUFACTURE . 31 AIRCRAFT PREPARATION AND WINGLET INSTALLATION . 37 FLIGHTPROGRAM ........................................................... 39 TestApproach ............................................................ 39 TestConditions ........................................................... 39 Aerodynamics ........................................................ 39 Structural and Aerodynamic Damping (Flutter1 ........................... 43 LoadsMeasurement ................................................... 44 Flight Instrumentation ..................................................... 46 Aerodynamics Data ................................................... 46 Flutter .............................................................. 47 Loads ............................................................... 47 FlightDataSystem ........................................................ 48 Preflight Ground Testing ................................................... 48 Ground Vibration Test (GVT) ........................................... 48 Strain Gauge Calibration Tests ......................................... 49 FlightTestProgram ....................................................... 49 RESULTSANDDISCUSSION .................................................. 53 BaselinePhase ............................................................ 53 FlightTestProgram .................................................. 53 Aerodynamics ........................................................ 53 LoadsMeasurement ................................................... 53 BasicWingletPhase ....................................................... 53 GroundVibrationTest ................................................. 53 FlightTestProgram .................................................. 54 Flutter .............................................................. 64 Low-SpeedBuffet ..................................................... 65 Low-Speed Drag ...................................................... 75 Stall Speeds and Characteristics ........................................ 76 CruisePerformance ................................................... 77 vii CONTENTS (Continued) Section Page Cruise Buffet ......................................................... 89 Longitudinal Static Stability ............................................ 90 Longitudina! Maneuvering Stability ..................................... 92 Longitudinal Trim Characteristics ....................................... 92 Static Directional Stability ............................................. 92 Dynamic Lateral Stability (Dutch Roll) .................................. 94 LoadsMeasurement ................................................... 94 Reduced-Span Winglet Phase ............................................... 95 FlightTestProgram .................................................. 95 Low-SpeedBuffet ..................................................... 99 Low-SpeedDrag ...................................................... 102 CruisePerformance ................................................... 103 IMPACT OF FLIGHT EVALUATION RESULTS ON OPERATIONALPERFORMANCE .............................................. 109 CONCLUSIONS ............................................................... 115 REFERENCES ............................................................... 117 APPENDIX A, FLIGHT TEST MEASUREMENT INDEX ......................... 119 APPENDIX B, PRESSURE ORIFICE LOCATIONS ............................... 141 . VIII I ILLUSTRATIONS Figure Page Winglet Model Under Development in NASA Langley 8-Foot Wind Tunnel ... 2 Key Events in the DC-10 Winglet Development Program ................... 3 Task Relationships in the DC-10 Winglet Development Program ............ 3 Test Aircraft with Basic Winglet ........................................ 4 ;a 5 Test Aircraft with Reduced-Span Winglet ................................ 5 6 Flow of Tasks ........................................................ 15 7 Flight Evaluation Program Schedule .................................... 16 8 Winglet Geometry Variations from Wind Tunnel Model .................... 17 9 Winglet Rigging to Account for Elastic Deflections ........................ 18 10 Principal Winglet Configurations from Application Studies ................. 19 11 Planned Winglet Geometry ............................................. 20 12 ContingencyConfigurations ............................................ 20 13 EnvelopeLimitations .................................................. 22 14 ManeuveringEnvelope ................................................ 22 15 Alternatives for Selection of Winglet Design Loads ........................ 23 16 Typical Estimated Spanwise Wing Lift Distribution ....................... 24 17 Winglet Installation Components
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