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A Design Study of a Proposed Four-Seat, Amateur-Built Airplane

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A Design Study of a Proposed Four-Seat, Amateur-Built Airplane University of Tennessee, Knoxville TRACE: Tennessee Research and Creative Exchange Masters Theses Graduate School 8-2003 A Design Study of a Proposed Four-Seat, Amateur-Built Airplane D. Andrew Moore University of Tennessee - Knoxville Follow this and additional works at: https://trace.tennessee.edu/utk_gradthes Part of the Mechanical Engineering Commons Recommended Citation Moore, D. Andrew, "A Design Study of a Proposed Four-Seat, Amateur-Built Airplane. " Master's Thesis, University of Tennessee, 2003. https://trace.tennessee.edu/utk_gradthes/2113 This Thesis is brought to you for free and open access by the Graduate School at TRACE: Tennessee Research and Creative Exchange. It has been accepted for inclusion in Masters Theses by an authorized administrator of TRACE: Tennessee Research and Creative Exchange. For more information, please contact [email protected]. To the Graduate Council: I am submitting herewith a thesis written by D. Andrew Moore entitled "A Design Study of a Proposed Four-Seat, Amateur-Built Airplane." I have examined the final electronic copy of this thesis for form and content and recommend that it be accepted in partial fulfillment of the requirements for the degree of Master of Science, with a major in Mechanical Engineering. Dr. Gary Flandro, Major Professor We have read this thesis and recommend its acceptance: Dr. Louis Deken, Dr. Peter Solies Accepted for the Council: Carolyn R. Hodges Vice Provost and Dean of the Graduate School (Original signatures are on file with official studentecor r ds.) To the Graduate Council: I am submitting herewith a thesis written by D. Andrew Moore entitled “A Design Study of a Proposed Four-Seat, Amateur-Built Airplane.” I have examined the final electronic copy of this thesis for form and content and recommend that it be accepted in partial fulfillment of the requirements for the degree of Master of Science, with a major in Mechanical Engineering. Dr. Gary Flandro Major Professor We have read this thesis and recommend its acceptance: Dr. Louis Deken Dr. Peter Solies Accepted for the Council: Dr. Anne Mayhew Vice Provost and Dean of Graduate Studies (Original signatures are on file with official student records.) A DESIGN STUDY OF A PROPOSED FOUR-SEAT, AMATEUR-BUILT AIRPLANE A Thesis Presented for the Master of Science Degree The University of Tennessee, Knoxville D. Andrew Moore August 2003 ii Dedicated to my Father who enabled me to fly and to Michael Reisman who showed me how. iii Acknowledgments The author wishes to express special appreciation to Dr. Gary Flandro, fellow sailplane enthusiast, advisor and head of my thesis committee, for allowing me the flexibility to pursue the design project herein. His patience with my many distractions balanced with his persistent encouragement were essential to the successful completion of this project. The author is additionally grateful to Dr. Lou Deken, thesis committee member and professor who taught many of the courses that provided the cornerstone for the work presented herein. Recognition and thanks go to Dr. Peter Solies for his valuable insights while participating on this thesis committee and especially for his unwavering dedication to the University soaring club all of these years. The author will be forever indebted to his wife Suzanne for providing inspiration by example and always believing in the successful completion of this project. iv Abstract An airplane configuration suitable for construction by an amateur builder without the need for complex factory fixtures and tooling has been developed. The proposed high-wing configuration is intended to carry a 600 LB payload of up to 4 passengers arranged in 2 rows of side-by-side accommodations at a design cruise speed of 145 kts. It has been shown that the cantilevered wing components of the low-wing, 2-seat Mustang II kit airplane are ideally suited for the proposed airplane when properly matched with strut braced inboard wing panels. The structural implications of optimally sized ailerons on the baseline Mustang II wing structure is presented. Wing, fuselage, and strut reaction loads have been determined for the proposed flight envelope. A steel tube cabin structure has been proposed and limited structural optimization accomplished using a finite- element model. Detail analysis of the wing/fuselage, wing/strut and strut/fuselage attachment fittings has been accomplished. v TABLE OF CONTENTS CHAPTER PAGE 1. INTRODUCTION..........................................................................................1 2. CONFIGURATION DEVELOPMENT...........................................................3 2.1 Mission.................................................................................................3 2.2 Configuration........................................................................................3 2.3 Construction.........................................................................................4 2.4 Engine/Propellor..................................................................................5 2.5 Initial Sizing..........................................................................................5 2.6 Center of Gravity Variation and Wing Placement................................9 2.7 Empennage Sizing and Placement....................................................12 2.8 Aileron Sizing.....................................................................................13 2.9 Landing Gear Arrangement...............................................................14 2.10 Composite Configuration Layout........................................................15 3. FLIGHT ENVELOPE..................................................................................18 3.1 Performance Estimate.......................................................................18 3.2 Structural Flight Envelope..................................................................22 4. WING LOADS............................................................................................28 4.1 Average Loads...................................................................................28 4.2 Span-wise Load Distribution..............................................................30 4.3 Outer Panel Loads.............................................................................30 4.4 Total Wing Attachment Reaction Loads............................................38 5. WING STRUCTURE...................................................................................43 5.1 General..............................................................................................43 5.2 Outboard Wing Panel Attachments...................................................43 5.3 Inboard Wing Panel Main Spar..........................................................45 5.4 Wing/Strut Attachment.......................................................................49 5.5 Forward Wing/Fuselage Attachment..................................................50 5.6 Aft Wing/Fuselage Attachment..........................................................51 6. FUSELAGE STRUCTURE.........................................................................54 6.1 Steel Cabin Frame.............................................................................54 6.2 Special Consideration to Lateral Reactions.......................................58 6.3 Fuselage Attachment Fittings............................................................60 vi CHAPTER PAGE 6.4 Wing Strut..........................................................................................63 7. CONCLUSIONS AND RECOMMENDATIONS..........................................67 7.1 Conclusions.......................................................................................67 7.2 Recommendations.............................................................................67 REFERENCES AND BIBLIOGRAPHY..............................................................68 VITA..................................................................................................................71 vii LIST OF TABLES TABLE PAGE 1. Wing Loading Comparison of Certified Aircraft.....................................8 2. Payload Effect on Center of Gravity......................................................12 3. Tail Volume Comparison.......................................................................13 4. Airfoil Characteristics.............................................................................22 5. Airplane Categories and Design Load factors.......................................22 6. Gust Load Factors.................................................................................26 7. Average Wing Aerodynamic Coefficients..............................................30 8. Outer Wing Panel Aileron-Deflected Torsion Estimate..........................36 9. Outer Wing Panel Reaction Load Components....................................38 10. Outer Wing Panel Combined Reaction Loads.......................................39 11. Wing Reaction Load Components.........................................................41 12. Wing Combined Reaction Loads...........................................................42 13. Material Mechanical Properties.............................................................43 14. Finite Element Model Applied Loads.....................................................56 15. Critical Fuselage Tube Properties.........................................................59 16. Summary of Fuselage Fitting Stresses..................................................64
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