Project Overview
The goal of this project was to design and construct an airfoil wing capable of withstanding a 90lb load applied to the wing tip. The assignment allowed for the design of the wing spar or beam to be modified as needed within given constraints and with changes made to the bulkheads of the wing to accommodate. Other aspects of the wing such as the symmetrical aero foil shape and bulkhead material were provided and could not be modified.
Structural analysis was conducted using PTC Creo’s Simulate application. The wing structure was simulated using full constraints on the fixed end (the end with the larger cross section) of the wing and a 90 lb force downwards on the free end of the wing. The final product was machined using a CNC milling machine using PTC Creo to generate the GCode program. As both sides of the workpiece need to be machined, a special apparatus with five holes was required to secure and keep the workpiece aligned and mounted for both machining phases. This was properly accounted for when designing, simulating, and milling the beam.
Key Contributions
Optimized Wing Spar Design:
I led the team in redesigning the wing spar, employing innovative techniques to achieve a balance between weight, tensile strength, and deflection. Through multiple iterations, we crafted a final design that surpassed performance expectations.
Material Selection and Simulation:
Utilizing advanced analysis tools, we conducted simulations to validate the use of 7075 T6 Aluminum for the wing spar. This material selection, coupled with meticulous design considerations, ensured the wing's ability to withstand load requirements while minimizing weight.
Stress profile
Deflection profile
Engineering Processes
• Employed PTC Creo's Simulate for structural analysis and optimization of the wing spar.
• Utilized CNC milling for precise machining of wing components from aluminum stock.
• Successfully achieved stress levels below the yield stress of the material, ensuring structural integrity under load conditions.
Loading and deflection test
Final Design Report
