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“Design and Analysis of Air to Air Refuelling Probe VISVESVARAYA TECHNOLOGICAL UNIVERSITY Jnana Sangama, Belgaum, Karnataka-590 014 A PROJECT REPORT ON “DESIGN AND ANALYSIS OF AIR TO AIR REFUELLING PROBE SUPPORT STRUCTURE” Project Report submitted in partial fulfillment of the requirement for the award of the degree of BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING Submitted by Melvin George 1NH15ME726 Navaneeth RN 1NH15ME732 Vijay P 1NH16ME428 Zuber J 1NH16ME433 Work was carried out in Aeronautical Development Agency, Bangalore Under the guidance of Internal Guide External Guide’s Mr. Rajesh A Mr. M Raghu Mr. Girish B Assistant Professor SC/ENGG ‘E’ SC/ENGG ‘G’ Dept. of Mechanical Engineering AF Dept. ADA AF dept, ADA NEW HORIZON COLLEGE OF ENGINEERING DEPARTMENT OF MECHANICAL ENGINEERING BANGALORE-560 103 2018-19 DEPARTMENT OF MECHANICAL ENGINEERING CERTIFICATE It is certified that the Project work entitled “Design and Analysis of Air to Air Refueling Probe Support Structure” carried out by MELVIN GEORGE (1NH15ME726), NAVANEETH RN (1NH15ME732), VIJAY P (1NH16ME428), ZUBER J (1NH16ME433), the bonafide students of New Horizon College of Engineering, Bengaluru, in partial fulfillment for the award of Bachelor of Engineering in Mechanical Engineering of the Visvesvaraya Technological University, Belgaum during the year 2018-2019. It is further certified that all corrections/suggestions indicated for internal assessment has been incorporated in the report deposited in the department library. The Project has been approved as it satisfies the academic requirements in respect of Project Work prescribed for the Bachelor of Engineering degree. Signature of the Guide Signature of the HOD Signature of the Principal Mr. RAJESH A Dr. M S GANESHA PRASAD Dr. MANJUNATHA Assistant Professor Dean, Prof. and HOD-ME Principal Dept. of Mechanical Engineering. Dept. of Mechanical Engineering. NHCE Name(s) of the student: University Seat Number: Melvin George 1NH15ME726 Navaneeth RN 1NH15ME732 Vijay P 1NH16ME428 Zuber J 1NH16ME433 External Viva Examiner Signature with date: 1. 2. ABSTRACT Aerial refueling allows the receiver aircraft to remain airborne for the longer time. It will increase the range and as Fighter jets can fly for only 2-3 hours doing a regular mission. The receiver aircraft can be topped up with extra fuel in the air, air refueling can allow a takeoff with a greater payload. It also increases the effectiveness of surveillance and patrol aircraft by allowing them to remain in the air longer The main aim of the project is to design a support structure that can withstand the load of the probe when it is engaging and disengaging with the refuelling drogue which is located on the mother aircraft and uniformly distribute the load to it. The various constraints faced while retrofitting are the space availability on the aircraft to accommodate the probe, also the LRU’s placed on various floor’s had to be moved around in order to accommodate the mounting bracket that holds the probe in place. v CONTENTS COLLEGE CERTIFICATE i COMPANY CERTIFICATE ii ACKNOWLEDGEMENT iii DECLARATION iv ABSTRACT v CONTENTS vi LIST OF FIGURES viii LIST OF TABLES xi NOMENCLATURE xii 1. INTRODUCTION ...................................................................................................... 1 1.1. Fixed Air to Air Refueling Probe ........................................................................... 1 1.2. Fuel Tanks ................................................................................................................ 2 1.3. Aerial Refueling ........................................................................................................ 3 1.3.1. Few Facts ......................................................................................................... 3 1.3.2. Objective of AAR System ................................................................................ 4 1.3.3. Disadvantages of AAR ..................................................................................... 4 1.4. Indian Air Force Transport Aircrafts......................................................................... 5 1.5. Types of Refueling Systems ...................................................................................... 6 1.5.1. Probe and Drogue ............................................................................................ 7 1.5.2. Flying Boom ................................................................................................... 11 2. LITERATURE REVIEW .............................................................................................. 13 3. NUMERICAL ANALYSIS ............................................................................................ 19 3.1. Moment Values About Fixed Point ....................................................................... 19 3.2. 1st load case moment values for θ = 0° using analytical approach ....................... 21 3.3. Verification of the moment 1st load case θ = 0° through Nastran & Patran ......... 24 3.3.1. HyperMesh v13.0 (Pre-processor) ................................................................ 24 3.3.2. Nastran v2016 (Solver) ................................................................................. 25 3.3.3. Patran v2016 (Post-processor) ..................................................................... 25 4. CAD MODEL ............................................................................................................ 27 4.1. Introduction to CATIA .......................................................................................... 27 4.2. CATIA Model of Probe and Mounting Bracket ..................................................... 27 5. FINITE ELEMENT ANALYSIS ...................................................................................... 31 5.1. Introduction to Finite Element Analysis ............................................................... 31 vi 5.2. Basic Concepts in Finite Element Analysis ........................................................... 31 5.2.1. Major Element Types .................................................................................... 31 5.2.2. Degrees of Freedom ..................................................................................... 32 5.2.3. Boundary Conditions .................................................................................... 32 5.3. FE Model Description ........................................................................................ 32 5.4. Bolt Connections ................................................................................................. 33 5.5. Material Description ............................................................................................ 33 5.6. Loads.................................................................................................................... 34 5.7. Boundary Conditions ........................................................................................... 35 5.8. Analysis Results ................................................................................................... 36 5.8.1. Normal Mode Analysis Result ....................................................................... 36 5.8.2. Natural Frequency Analysis Result ............................................................... 37 5.8.3. Max-Displacement Result ............................................................................. 38 5.8.4. Reaction Forces ............................................................................................ 39 5.8.5. Bar Forces ..................................................................................................... 40 5.8.6. Von Mises Stress Results .............................................................................. 41 5.8.7. Max Principal Stress Results ......................................................................... 43 6. CONCLUSION .......................................................................................................... 44 7. SCOPE OF FUTURE WORK........................................................................................ 45 REFERENCES ........................................................................................................ 47 vii LIST OF FIGURES FIG NO TITLE PAGE NO 1.1 LOCATION OF THE FIXED AIR TO AIR REFUELING PROBE 1 1.2 THE VARIOUS FUEL TANKS LOCATED ON A FIGHTER JET 2 1.3 DROP TANK 3 1.4 THE BERIEV A-50 IS A SOVIET AIRBORNE EARLY WARNING 5 AND CONTROL (AEW&C) 1.5 ILYUSHIN IL-76-TRANSPORT AIRCRAFT IAF 6 1.6 ILYUSHIN IL-78MKI HAS A REFUELING RATE OF 500-600 6 LITRES A MINUTE, CAN FERRY UP TO 118 TONS OF FUEL 1.7 FLOWCHART SHOWING THE VARIOUS METHODS OF FUEL 7 RECEIVING METHODS ON THE RECEIVING AIRCRAFT 1.8 F-35B WITH A RETRACTABLE PROBE REFUELING THROUGH 7 PROBE AND DROGUE 1.9 MIRAGE 2000 WITH A FIXED PROBE REFUELING THROUGH 8 PROBE AND DROGUE 1.10 F-35A 8 1.11 MIRAGE 2000 9 1.12 PROBE AND DROGUE SYSTEM 10 1.13 F-22 RAPTOR 11 2.1 MIRAGE 2000 - FIXED AAR PROBE (SIDE VIEW) 13 2.2 MIRAGE 2000 - FIXED AAR PROBE (TOP VIEW) 13 2.3 RAFALE - FIXED AAR PROBE (SIDE VIEW) 14 2.4 RAFALE - FIXED AAR PROBE (SIDE VIEW) 14 2.5 RAFALE - FIXED AAR PROBE (SIDE VIEW) 15 2.6 RAFALE - FIXED AAR PROBE (FRONT VIEW) 15 2.7 AERMACCHI M-345 - FIXED AAR PROBE (SIDE VIEW) 16 2.8 AERMACCHI M-345 - FIXED AAR PROBE (SIDE VIEW) 16 2.9 AERMACCHI M-345 - FIXED AAR PROBE (FRONT VIEW) 16 viii 2.10 F18 WITH RETRACTABLE AERIAL REFUELING PROBE 17 2.11 PANAVIA TORNADO WITH AERIAL REFUELING PROBE 17 2.12 TYPHOON WITH RETRACTABLE AERIAL REFUELING PROBE
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