Design Report

Presented by Aeronyx Club of MS Ramaiah

University of Applied sciences

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 Abstract
This report contains the study and development of a highly manurable plane that
is capable of carrying a payload of 200 grams. It also presents the detailed
conceptual design of the aircraft. In addition, the report discusses
interpretations, calculations of propulsion systems, batteries and other working
mechanisms.
Structural analysis with respect to stress-strain curves, materials used for
construction, load analysis, geometry and also the power plant details are
included in the report.
Weight estimation of all given components along with their given specifications
and configurations is also presented.
Software like FUSION 360 and Open VSP were used to build and analyse the
aircraft and the results are presented in detail in this report.

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 Table of Contents
1 Abstract........................................................................................................... 2
2 Introduction .................................................................................................... 5
2.1 Design problem......................................................................................... 5
2.2 Approach .................................................................................................. 5
3 Weight Estimation ........................................................................................... 6
4 Power Plant Selection ..................................................................................... 7
4.1 Motor ....................................................................................................... 7
4.2 ESC ............................................................................................................ 7
4.3 Battery ...................................................................................................... 7
4.4 Propeller ................................................................................................... 7
5 Aerodynamics ................................................................................................. 8
5.1 Introduction .............................................................................................. 8
5.2 Analysis ..................................................................................................... 8
5.3 Description of the airfoil ........................................................................... 8
5.3.1 Nomenclature and Shape .................................................................. 8
5.3.2 Geometry .......................................................................................... 9
5.3.3 Aerodynamic Characteristics ............................................................. 9
[Figure: Cp distribution]............................................................................ 11
[Figure: Cl/alpha & Cl-Cd graph] .............................................................. 11
6 FABRICATION ................................................................................................. 12
6.1 Wing ....................................................................................................... 12
6.2 Fuselage.................................................................................................. 12
6.3 Dropping Mechanism.............................................................................. 12
6.4 3D Design................................................................................................ 13
[Figure: Top view] ..................................................................................... 13
[Figure: Front view] .................................................................................. 13
[Figure: Side view] .................................................................................... 13
[Figure: Isometric projection] ................................................................... 13
7 CG Estimation................................................................................................ 14
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 7.1 Wing ....................................................................................................... 14
7.2 Fuselage.................................................................................................. 14
8 Control Surfaces ............................................................................................ 15
8.1 Horizontal Stabilizer ........................................................................... 15
8.2 Vertical stabilizer ................................................................................ 16
8.3 Elevator .............................................................................................. 16
8.4 Payload............................................................................................... 17
9 BILL Of MATERIALS ........................................................................................ 18
10 Innovation ................................................................................................... 19
10.1 Material Used ....................................................................................... 19
10.2 Dropping Mechanism................................ Error! Bookmark not defined.
11 Conclusion .................................................................................................. 19
12 Team members ........................................................................................... 20

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 Introduction

Design problem
To fabricate an aircraft which is capable of carrying 200g of static payload and
perform maneuverers that includes a “360 fly-by” with the same starting and
end points.

Approach
In order to satisfy and accomplish the given goals, we have come up with a
design solution that includes
• Initial material analysis
• 2D design conceptualization
• 3D model creation
• Air foil analysis
• Structural analysis
• Payload mechanism design
• Selection of materials and parts
• Cost analysis of parts
• Final design run through
• Building of the airplane

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 Weight Estimation

We obtained a total weight of 684g without the payload. With payload the
total weight comes to 884g.

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 Power Plant Selection

Motor
• Here we are using a DYS D2826-10 1400KV Outrunner BLDC Motor.
• Paired with an 8inch propeller it is capable of producing 900g of thrust.
Which is enough amount of thrust required to perform the given task
and accomplish the goals.
• The motor has a great advantage when it comes to weight, weighing in
at just 50g, with a max power output of 205W having great thrust to
power ratio.
• Dimensions of the motor:

Fig: 1

ESC (Electronic Speed Controllers)

• Popularly known in the field, a Simon-k 40A ESC is enough to deliver
sufficient power needed to run 8inch propellers without overheating.
• The ESC comes with a built in BEC (Battery Eliminator Circuit) which
supplies a constant voltage of 5V to the receiver to power the servos and
other components.

Battery
• A wolfpack 1500mAh 3-s (3 cells) providing an output of 35C of charge.
• Connected with an XT-60 connector.
• Dimensions of L:104mm, B:34mm, H:23mm.

Propeller
• 8045 propellers are used. They can produce the required thrust, which is
900g.

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 Aerodynamics
Introduction
• The NACA 4412, a well know airfoil used for swift and maneuverable
flight.
• With a higher stall angle at even increased Angle of Attacks.
• Stall Angle : 110 at Re of 1,00,000.
• Lift coefficient of 1.5 at pre-stall

Analysis
• For this lift calculation we have used Eppler standard instead of Calcfoil
due to its more accurate results.
• As it can be noted that the CL reaches 1.5 at around 10 degrees
• The Cl vs CD graph shows a gradual fall off rather than a coarse bucket
which shows its performance does not drop off in adverse maneuvering
operations
• The pressure distribution also shows an even break, only maximum at
the leading-edge areas showing a clean streamline over the surface area
• The given attributes of this airfoil and its general ease of use has landed
itself as the conclusive airfoil of choice for our design.

Description of the airfoil

The NACA 4412 airfoil is a widely used airfoil design developed by the National
Advisory Committee for Aeronautics (NACA), the predecessor of NASA. The
NACA four-digit airfoil series is a family of airfoils that describes the shape and
aerodynamic characteristics through a standardized system. Let's break down
the NACA 4412 in detail:

Nomenclature and Shape

• First digit (4): Maximum camber is 4% of the chord length.
• Second digit (4): The location of the maximum camber is at 40% of the
chord length from the leading edge.
• Third and fourth digits (12): Maximum thickness is 12% of the chord
length.

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Geometry
• Camber: The camber line defines the curvature of the airfoil, with the
NACA 4412 having a relatively moderate camber which helps in
generating lift at lower angles of attack.
• Thickness: The maximum thickness of the airfoil is 12% of the chord
length. This means if the chord length is 1 meter, the maximum thickness
is 0.12 meters.
• Leading Edge Radius: It has a rounded leading edge which helps in
delaying flow separation and reducing the chances of a stall at lower
angles of attack.
• Trailing Edge: The trailing edge is typically sharp in standard NACA
airfoils, helping in reducing pressure drag.

Aerodynamic Characteristics
• Lift Coefficient (Cl): The NACA 4412 generates significant lift, making it
suitable for applications requiring high lift at relatively low speeds.
• Drag Coefficient (Cd): The drag coefficient remains relatively low at lower
angles of attack, but increases as the angle of attack increases.
• Moment Coefficient (Cm): The pitching moment is moderate, which
indicates a relatively stable behavior in most flight conditions.
• Stall Characteristics: It stalls at a moderate angle of attack, and the stall is
relatively gentle and predictable, which is advantageous for many aircraft
applications.
• Applications
• Aircraft Wings: The NACA 4412 is commonly used in light aircraft and
general aviation due to its favorable lift characteristics and gentle stall
behavior.
• Wind Turbines: Its design is also suitable for use in wind turbine blades,
where efficient lift at low speeds is crucial.
• Propeller Blades: The airfoil's properties make it suitable for use in
propellers, where it can provide the necessary lift and thrust efficiently.

In summary, the NACA 4412 airfoil is a versatile and well-studied airfoil with a
good balance of lift and drag characteristics, making it suitable for a variety of
aerodynamic applications. Its design principles and performance data are well

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documented, which has contributed to its widespread use and continued
relevance in both academic and practical aerodynamics.

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Fig: 2

Fig: 3

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 FABRICATION
Fabrication as a whole is the selection of the right materials required to build any machine in
such a way that it can handle all foreign and external forces that it will be subjected to. Keeping
this in mind we ran simulations and conducted analysis for various factors affecting the
machine and made sure its reliability and safety were intact even under extreme conditions.

A combination of Depron Foam Sheets along with Balsa wood of varying thicknesses have
been used in developing this aircraft to achieve the required goal in completing the aircraft.

Wing
• The wing has been completely designed and fabricated using balsa wood, laser cut to
into desired thicknesses.
• The Aerofoil and the spar are made using 3mm Balsa wood sheets, the skin of the
aerofoil at the leading and trailing edge is made using 1mm Balsa wood sheets.
• Servo motors are placed inside the wing to control the ailerons which is made using
3mm Balsa wood sheets hinged to the wing using fibre tape for smooth motion and
reduced weight.
• A layer of covering film is used to cover the skeleton structure of the wing and
provide the aerofoil shape to the wing.

Fuselage
• The fuselage carrying majority of the load and components, must be made using a
lightweight and rigid material.
• A Depron foam sheet, 5mm in thickness is used to make the complete fuselage.
• The fuselage, is designed on XFLR and cut out on foam sheets, glued together using
hot glue.
• Special attention is given to the bay area since the aircraft has to perform a belly
landing, 5mm balsa is reinforced on the bottom half and fibre tapes on the remaining
ends.
• Bamboo skewer have been placed horizontally to hold the wings in place, and a piece
of vinyl wood has been used as a firewall for the motor mount.

Dropping Mechanism
• The most important mechanism of the aircraft is the dropping mechanism, which
helps us to drop the payload to the assigned target and thus completing the mission
in ease.
• To prevent any hassle and complicated designs, we have gone ahead with the
traditional “Bomb Dropping Mechanism” design.
• Using balsa on the underside of the fuselage connected to one servo motor, this
release mechanism is very reliable and much simpler to construct.

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 3D Design

[Fig 4: Top view]

[Fig 5: Front view]

[Fig 6: Side view]

[Fig 7: Isometric
projection]

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 CG Estimation

Wing
Wing Span- 990mm.
Aerodynamic Centre
The aerodynamic centre (AC) is a critical concept in aerodynamics, particularly
in the analysis and design of aerofoils and wings. It is defined as the point along
the chord line of an aerofoil where the moment coefficient (Cm) about that point
is independent of the angle of attack. This implies that, at the aerodynamic
centre, the pitching moment remains constant regardless of changes in lift due
to variations in the angle of attack. Chord (c) = 200mm
Quarter Chord Length
Area of the wing = wing span x chord
= 990 x 200
= 198000mm²
AC = 200 x 0.25
= 50mm
Wing aspect ratio = wing span /wing root chord
= 990/200
= 4.95

Fuselage
• Fuselage Length
= wingspan x 0.75 (75% of wing span)
= 990 x 0.75
= 742.5mm
≈ 750mm

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 • Nose Length
Nose length of the aircraft is usually 20% of fuselage length,
measured from the tip of the propeller to the wings leading edge
= 750 x 0.2
= 150mm.
• Tail Length
The length of the aircrafts tail is the distance from the wings
trailing edge to the horizontal stabilizer leading edge usually 40%.
Tail length = 750 x 0.53
= 400mm.

Control Surfaces
Horizontal Stabilizer
The area of the horizontal stabilizer should be 20% of the area of the wing
• Sweep angle = 33.5⁰
• Area of the wing = wing span x chord
= 990 x 200
= 198000mm²
• Root Chord = 18.5 cm
• Tip Chord = 7 cm
• Average chord = (18.5+7) ÷ 2
= 12.75 cm
Theoretical Calculation
Area of horizontal stabilizer = wing area x 0.2
= 198000 x 0.2
= 39600mm²

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 • Final results after fabrication
Horizontal Area = Average chord x wing span
= 12.75 x 30
= 382.5cm²
= 38250mm²

Vertical stabilizer
The area of the vertical stabilizer should be 10% of the area of the wing.
• Sweep angle = 33.5⁰
• Root Chord = 18.5 cm
• Tip Chord = 4.5 cm
Average chord = (18.5+4.5) ÷ 2
= 11.5

• Area of vertical stabilizer

= 11.5 x 16.5
= 1897.5mm²

Elevator
Area of the elevator should be 25% of the area of the horizontal
stabilizer.

• Theoretical calculations
Area of elevator = area of horizontal stabilizer x 0.25
= 39600 x 0.25
= 9900mm²

• Final result after fabrication

Area of elevator = 300 x30
= 9000mm²

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Payload

Dimensions of Payload:
• Length = 20cm
• Breadth = 5 cm
• Height = 5 cm
• Total volume= 500 cm3

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 BILL Of MATERIALS
Components Quantity
DYS D2826-10 1400kv DYS Motor 1
Tower Pro 9g Servo Motors 4
Turnigy 30A ESC 1
8*4 Nylon Propeller 1
5mm Depron Foam Sheets 1
5mm Balsa Wood 1
3mm Balsa Wood 2
1mm Balsa Wood 1
2.5mm Balsa Wood 1
Orange 1500-3s 35c Li-poli Battery 1
FS-i6 Transmitter and Receiver 1

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 Innovation

Material Used
Depron sheets by themselves have low tensile strength, we have used balsa
sheets to strengthen them and create a solid barrier. This gives immense
strength to the aircraft model keeping the weight low at the same time.

Dropping Mechanism
As mentioned earlier a “bomb Dropping” mechanism is being used on this
aircraft. This is much easier to construct and a very simple design. Thus, making
it cheap for constructing as well.

Conclusion
The aircraft built for this competition is based on the competition requirements
and has been built the most optimal way for the aircraft to perform a power
loop while carrying a payload of 200 gm. The design, calculation and analysis
were completely done inhouse for performance. The plane is completely
functional in all the ways and will be able to perform the said tasks with ease
and precision. The drop mechanism is based on bomb dropping mechanism to
keep precision for dropping the payload and keep minimal error range. The
fabrication was done using laser cut balsa for the wing components and the
covering was also done inhouse.

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 Team members
Role Name Roll number

Advisor Dr. Jayahar Sivasubramanian

Leader Navneeth Arasu 22ETAS012022

Member Karthik R P 22ETAS102019

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