Design and Development of a Multi- Mission UAS through Modular Component Integration and Additive Manufacturing A project present to The Faculty of the Department of Aerospace Engineering San Jose State University in partial fulfillment of the requirements for the degree Master of Science in Aerospace Engineering By Kim Lau August, 2018 approved by Dr. Nikos Mourtos Faculty Advisor 2 Table of Contents 1. Introduction ........................................................................................................................5 1.1. Motivation .................................................................................................................5 1.2. Literature Review .....................................................................................................5 1.2.1. UAV Design and Development Trends ...........................................................5 1.2.2. Push for Modularity .........................................................................................7 1.2.3. Additive Manufacturing ...................................................................................8 1.3. Project Proposal ........................................................................................................11 1.4. Methodology .............................................................................................................11 2. Design Process ...................................................................................................................12 2.1. Mission Specification and Comparative Study .........................................................12 2.1.1. Mission Specification ......................................................................................12 2.1.1.1. Mission Specification .............................................................................12 2.1.1.1.1. Surveillance ...................................................................................12 2.1.1.1.2. Attack .............................................................................................13 2.1.1.1.3. Resupply ........................................................................................13 2.1.1.2. Mission Profile ........................................................................................13 2.1.1.2.1. Surveillance ...................................................................................13 2.1.1.2.2. Attack .............................................................................................14 2.1.1.2.3. Resupply ........................................................................................14 2.1.1.3. Critical Mission Requirements ...............................................................15 2.1.2. Comparative Study of Similar Airplanes .........................................................15 2.1.2.1. Mission Capabilities and Configuration Selection .................................15 2.1.2.2. Comparison of Important Design Parameters .........................................15 2.2. Configuration Design ................................................................................................16 2.2.1. Comparative Study of Airplanes with Similar Mission Performance .............16 2.2.1.1. Comparison of Weights/Performance/Geometry of Similar Airplanes ..16 2.2.1.2. Configuration Comparison of Similar Airplanes ....................................17 2.2.1.2.1. AliExpress SkyEye ........................................................................17 2.2.1.2.2. Applied Aeronautics Albatross ......................................................18 2.2.1.2.3. Optimum Solutions Condor 300 ....................................................18 2.2.1.2.4. Optimum Solutions Leonardo ........................................................19 2.2.1.2.5. Penguin BE Electric .......................................................................19 2.2.1.2.6. RQ-11 Raven .................................................................................20 2.2.1.2.7. RQ-14 Dragon Eye ........................................................................20 2.2.1.2.8. RQ-20 Puma ..................................................................................21 2.2.1.2.9. Bye Aerospace Silent Falcon .........................................................21 2.2.1.2.10. SkyPro V200 ................................................................................21 2.2.1.2.11. Discussion ....................................................................................22 2.2.2. Configuration Selection ...................................................................................22 2.2.2.1. Overall Configuration .............................................................................22 2.2.2.2. Wing Configuration ................................................................................22 2.2.2.3. Empennage Configuration ......................................................................22 2.2.2.4. Integration of the Propulsion System......................................................22 2.2.2.5. Landing Gear Disposition .......................................................................22 2.3. Weight Sizing & Weight Sensitivities ......................................................................22 3 2.3.1. Mission Weight Estimates ...............................................................................23 2.3.1.1. Database for Takeoff/Empty Weights of Similar Airplanes ...................23 2.3.1.2. Determination of Regression Coefficients A and B ...............................23 2.3.1.3. Determination of Mission Weights .........................................................24 2.3.1.4. Takeoff Weight Sensitivities ..................................................................26 2.3.1.4.1. Calculation of Takeoff Weight Sensitivities ..................................26 2.3.1.4.2. Trade Studies .................................................................................26 2.4. Performance Constraint Analysis .............................................................................27 2.4.1. Calculation of Performance Constraints ..........................................................27 2.4.1.1. Stall Speed ..............................................................................................27 2.4.1.2. Takeoff Distance .....................................................................................28 2.4.1.3. Landing Distance ....................................................................................28 2.4.1.4. Drag Polar Estimation .............................................................................30 2.4.1.5. Climb Constraints ...................................................................................30 2.4.1.6. Speed Constraints ...................................................................................31 2.4.1.7. Summary of Performance Constraints ....................................................32 2.4.2. Selection of Propulsion System .......................................................................33 2.4.2.1. Selection of the Propulsion System Type ...............................................33 2.4.2.2. Selection of the Number of Engines .......................................................33 2.4.3. Discussion ........................................................................................................35 2.5. Fuselage Design ........................................................................................................35 2.5.1. Layout Design of the Fuselage ........................................................................35 2.6. Wing, High-Lift System & Lateral Control Design .................................................37 2.6.1. Wing Planform Design ....................................................................................37 2.6.2. Airfoil Selection ...............................................................................................39 2.6.3. Wing Design Evaluation ..................................................................................43 2.6.4. Design of the High-Lift Devices and Lateral Control Surfaces .......................43 2.6.4.1. High-Lift Devices ...................................................................................43 2.6.4.2. Lateral Control Surfaces .........................................................................46 2.6.4.3. Layout of High Lift Devices and Lateral Control Surfaces ....................48 2.7. Design of the Empennage & the Longitudinal and Directional Controls .................48 2.7.1. Overall Empennage Design .............................................................................48 2.7.2. Design of the Horizontal Stabilizer .................................................................50 2.7.3. Design of the Vertical Stabilizer ......................................................................51 2.7.4. Design Of The Longitudinal And Directional Controls ..................................53 2.7.4.1. Longitudinal Control ..............................................................................53 2.7.4.2. Directional Control .................................................................................55 2.8. Landing Gear Design and Weight & Balance Analysis ...........................................57 2.8.1. Estimation of the Center of Gravity Location for the Airplane .......................57 2.8.2. Landing Gear Design .......................................................................................58