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BE RESEARCH PAPER Final

This document discusses the design optimization of a drone frame through topology optimization to reduce weight. The original drone frame model was created in CATIA V5 and imported into ANSYS for topology optimization. Stress analysis showed maximum stress areas near motor mount holes. Topology optimization removed material from low stress areas, achieving a 50% mass reduction without exceeding stress limits. The optimized polyethylene frame mass reduced from 11.237kg to 6.3695kg, significantly lowering material usage and production costs.

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Hrithik Zimal
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153 views3 pages

BE RESEARCH PAPER Final

This document discusses the design optimization of a drone frame through topology optimization to reduce weight. The original drone frame model was created in CATIA V5 and imported into ANSYS for topology optimization. Stress analysis showed maximum stress areas near motor mount holes. Topology optimization removed material from low stress areas, achieving a 50% mass reduction without exceeding stress limits. The optimized polyethylene frame mass reduced from 11.237kg to 6.3695kg, significantly lowering material usage and production costs.

Uploaded by

Hrithik Zimal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Design Optimization of Drone Frame

Shubham Bajirao Maingade 1, Prathamesh Vijay Kadam 2, Raj Sudhir Gole 3, Hritik Pandurang Zimal 4,
Prasanna Raut 5
1
BE Mechanical Engineering, Saraswati College of Engineering, Kharghar, Navi Mumbai, India, shubhammaingade20002gmail.com
2
BE Mechanical Engineering, Saraswati College of Engineering, Kharghar, Navi Mumbai, India, [email protected]
3
BE Mechanical Engineering, Saraswati College of Engineering, Kharghar, Navi Mumbai, India, [email protected]
4
BE Mechanical Engineering, Saraswati College of Engineering, Kharghar, Navi Mumbai, India, [email protected]
5
Assistant Professor, Saraswati College of Engineering, Kharghar, Navi Mumbai, India, [email protected]

Abstract: Frame is one of the important component of any drone. A Drone Frame model is prepared using CATIA V5.Then it is
In this paper we are optimizing the frame design with the help of imported to ANSYS 19 R3 for topology optimization. Frame has
ANSYS topology optimization so it’s weight can be reduced. Drone 11.237 Kg mass with Polyethylene material and 26 Kg with Carbon
frame design is optimized so it can carry heavy load with reduced Fibre before Topology Optimization.
frame weight. This will result in material reduction and help to
improve the performance of drone. BOUNDARY CONDITIONS

Key words: Drone frame, Topology Optimization, Material


Reduction

INTRODUCTION: Recent years have shown that unmanned aerial


vehicles (UAV), commonly termed ‘drones’, have the potential to
become an iconic technology of the 21st century. Drones combine
three key principles of technological modernity - data processing,
autonomy and boundless mobility. They provide access to (new)
spaces and enable their analysis with the help of unprecedented
methods of data collection. These capabilities, previously a
privilege reserved to the military, are now increasingly
incorporated into civil domains. Thus, drones generate potential
use-cases ranging from surveillance/sensing missions to novel Fig 2. Boundary Conditions
forms of logistics and passenger transportation. Regardless of
their application, drones are driven by a general motivation to Drone stand (A) is considered as fixed support for this study. The
make processes faster and more flexible, while improving motor thrust of 130 N is considered for this study.This load
precision and cost-efficiency. condition is applied at motor mount (C) in upward direction. The
In this paper Drone Frame is studied for design improvement. weight to be lifted as well as weight of the components like
Comparing the polyethylene and Carbon Fibre results obtained motors, battery, flight controller and electronic speed controller
from topology optimization it is concluded that it is possible to are all assumed to be 350 N. this load case is applied in the
reduce weight of frame by using Polyethylene as well as Carbon downward direction (B).
Fibre without compromising load carrying capacity.
Meshing Details
DETAILS OF MODEL

Fig 3. Meshing details

Fig 1.Model of Drone Frame While doing an analysis CFD Fluent Solver is used and Tetrahedron
element with Patch confirming algorithm is used.
STRESS ANALYSIS TOPOLOGY OPTIMIZATION RESULTS

Fig 6. Topology optimization result


Fig 4. Stress Analysis before optimization
ANSYS removed material from low stress area in order to achieve
The above figure represents the stress distribution on
50% mass reduction without affecting limit stresses.
the frame. The blue color region represents the low stress area
and the red region represents the max stress area. The maximum
stress is 3.036 MPa i.e. near the motor mount holes on the arms.
It is possible to reduce material where there is low stress area. MASS REDUCTION AFTER TOPOLOGY
Therefore mass of the frame can be reduced.

MASS ANALYSIS WITH POLYETHYLENE

Fig 7.Mass reduction

Mass of the Polyethylene frame reduced to 6.3695 Kg after


topology optimization with 50% material reduction.
Fig 5.Original mass of model with Polyethylene
OPTIMIZED MODEL
Original mass of the drone frame before topology optimization
with polyethylene material is 11.237 Kg. As there is possibility of
material reduction this mass can be reduced after topology
optimization.

Fig 8.Optimized model

After topology optimization geometry of model changes


drastically so final model is prepared using CATIA V5.
STRESS ANALYSIS OF FINAL RESULT REFERENCES
[1] Le, D. K., & Nam, T. K. (2015). A study on the modeling of a
hexacopter. Korean Marine Engineering Journal, 39(10),
1023-1030.
[2] Saleel Visal and Swapnil U Deokar paper on " Carbon fibre
and Reinforced polymers ", International
ernational Journal for
Innovative Research in Science & Technology (IJIRST)-
(IJIRST) vol. 2
issue 12 May 2016
[3] Obli, P. N. (June 2020). Quadcopter frame optimization.
ResearchGate.
[4] Baránek, Radek, and František Šolc. "Modeling and control
of a hexacopter." Carpathian Control Conference (ICCC),
2012 13th International. IEEE, 2012
Fig 9. Stress Analysis Report [5] D. Wang, "Quadcopter Parts: What are they and what do
they do? – Quadcopter Academy", Quadcopter Academy,
The above figure represents the stress distribution on the frame. 2017.
The blue color region represents the low stress area and the red
region represents the max stress area. The maximum stress is
4.8221 MPa.

CONCLUSION

Topology optimization significantly reduces the material


required in the Drone Frame. Here 50% % of weight reduction is
achieved. This design improvement in component can be used in
various ways. Firstly, the weight of the part is reduced thus the
cost of production.

Original Mass 11.237 Kg

Reduced Mass 6.36 Kg

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