Senior Capstone Design Class

Project “Volcan”: Aircraft Design

Aircraft Design Team AY 99-00 (left to right): Hamed Kebriaei, Stephen Kwong, Wade Willams, Tim Jackson (far back), Chris Italiano, Sara Brandenburg, Erick Swanson, Lorenzo Locante, Lisa Parkin, Jo-Einar Emblemsvåg , Dan Hitchcock, Abbey Eichman, Johan Bakken, Tom Hompland, Scott Munson, Colin Kerelchuk.

The Aircraft Team designed a four-place airplane and was organized into five disciplines led by two project managers. The System Layout/Weights discipline used Pro/ENGINEER software to physically integrate all the airplane components: several different cabin layouts were considered until the optimal arrangement was found. They used a weight-and-balance spreadsheet to locate components such that the final airplane weight-and-balance was within the Aerodynamic allowable weight-and-balance limits 3625 lbs maximum takeoff weight.

The Aerodynamics discipline determined the allowable weight-and-balance limits by examining longitudinal static stability and control characteristics. Airplane configuration was also chosen to meet performance criteria. The airplane ended up with a 34 ft wing span and 29 ft length. The Structures discipline researched new composite materials and new construction methods to fabricate the aircraft. Pro/ENGINEER was used to design a retractable tricycle landing gear.

The Cockpit Systems discipline was responsible for selecting and arranging the airplanes avionics, controls and other systems which require pilot interface.

Each student was required to actively participate in their chosen discipline and meet as a team on a weekly basis to present and discuss design issues. The Project Managers organized and conducted these meetings. The aircraft team successfully presented their design at a formal Conceptual Design Review at the end of Fall Semester.

The Aircraft Design Team was reorganized during Spring Semester into the following groups: Windtunnel Group, Structures Group, Cabin Mockup Group, Radio Controlled (RC) model group, and Data Acquisition group for the RC model.

The Wind tunnel test group consisted of four students, who built an 8 % scale wind tunnel model of the Vulcan and tested it in the AEM 38 x 54 inch re-circulating wind tunnel. Pro/ENGINEER was used to NC machine the airplanes wings, horizontal stabilizer, and a left/right side male mold of the fuselage (vacuum formed with hot plastic). They successfully determined that the airplane was longitudinally stable and controllable. Flow visualization around the aircraft was also done in order to compare the flow pattern to the experimental data.

The Structures group consisted of two students, who built a half scale wing using Hexcel composite material in order to evaluate the wing under different loading conditions.

The cabin mockup group consisted of four students who built a full scale mockup of the airplanes interior including the cockpit and the instrumentation panel to evaluate human ergonomics, the chosen seating configuration, and to minimize cabin cross-section. The instrument panel was modeled using X-Plane simulation software.

Building the 1/4th Scale model: Dan Snyder, Scott Munson, Johan Bakken, Wade Williams.

Five students built a ¼th scale RC model with the goal of flying it by the end of Spring semester. The students used Pro/ENGINEER and NC machining to fabricate parts for a conventional RC model construction (balsa wood with monocote covering)

A Data Acquisition System (DAS) group of two students used a data logger data acquisition system along with sensors to measure dynamic pressure, angle of attack, normal acceleration, and elevator throttle and position. The other responsibility of the DAS group was to make sure that the data acquisition unit did not interfere with the pilots control input.

All aircraft testing and flying was done at Jensen airfield in Rosemount, Minnesota. Toni Riga from the Tri-Valley Flyers RC club volunteered to be their pilot because the students had limited experience flying radio controlled models.

The RC team took several trips to Jensen airfield. The first trip to Jensen airfield was to break in the engine. The second trip to Jensen field was to perform high-speed taxiing. On the first flight Toni carefully brought the RC model to five feet off the ground for a distance of approximately 50 feet. The RC model touched down and quickly cut to its right, shooting off the runway and into some corn stalks. The damage was minimal and the propeller was broken.

After adding twist to the wing, and fixing the minor damage, the RC model was ready for its next flight. The plan was to fly a racetrack pattern around the runway. The takeoff was successful. The RC speed was an estimated 25 mph and then climbed to an estimated altitude of 40 feet. The RC model then lined up with the runway and glided in to a perfect three-point landing. The RC model was a success.

The Volcan design team paused after a successful day at the Jensen Airfield field with Toni Riga (third from left).