The project involved redesigning and testing the fuselage of a micro aerial vehicle to meet specifications for impact resistance and manufacturing. Research was conducted on materials, resins, and processes. The original 4-part design was simplified to a 2-part design using carbon fiber and vinyl ester resin in a vacuum infusion process. Testing showed the design withstood impacts of 30 degrees at 20 m/s with minimal damage. Quotes were obtained from manufacturers for production but constructing parts in-house was recommended for low volumes due to quality control.
The project involved redesigning and testing the fuselage of a micro aerial vehicle to meet specifications for impact resistance and manufacturing. Research was conducted on materials, resins, and processes. The original 4-part design was simplified to a 2-part design using carbon fiber and vinyl ester resin in a vacuum infusion process. Testing showed the design withstood impacts of 30 degrees at 20 m/s with minimal damage. Quotes were obtained from manufacturers for production but constructing parts in-house was recommended for low volumes due to quality control.
The project involved redesigning and testing the fuselage of a micro aerial vehicle to meet specifications for impact resistance and manufacturing. Research was conducted on materials, resins, and processes. The original 4-part design was simplified to a 2-part design using carbon fiber and vinyl ester resin in a vacuum infusion process. Testing showed the design withstood impacts of 30 degrees at 20 m/s with minimal damage. Quotes were obtained from manufacturers for production but constructing parts in-house was recommended for low volumes due to quality control.
The project involved redesigning and testing the fuselage of a micro aerial vehicle to meet specifications for impact resistance and manufacturing. Research was conducted on materials, resins, and processes. The original 4-part design was simplified to a 2-part design using carbon fiber and vinyl ester resin in a vacuum infusion process. Testing showed the design withstood impacts of 30 degrees at 20 m/s with minimal damage. Quotes were obtained from manufacturers for production but constructing parts in-house was recommended for low volumes due to quality control.
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Composite Manufacturing
Group 15 Eglin AFB
Brandon Bair - John Brewer - Darnell Brown - Rob Contes
Sponsor: Jeff Wagener - Lt Joe Czabarnek, AFRL
Faculty Advisors: Dr. Chiang Shih (ME) - Dr. Richard Liang (IE) Introduction
• Scope • Design Development
• AFRL Fuselage • Construction Specifications • Testing • Project Specifications • Hiring • Research • Conclusions • Selection • Recommendations • Original Design • Summary • Questions Scope
The scope of this project was to redesign and test
the fuselage of the Bullwinkle Micro Aerial Vehicle and “hire” a manufacturer to produce it. AFRL Fuselage
• Length - 15.75” • Width - 2.25” • Height - 2.25’’ • Construction • 2 part Design • Male mold • Pre-impregnated carbon fiber • Assembled with nylon screws • Motor Mount – Sheet aluminum Project Specifications
• Same size and shape
• Survive a 30o impact at 20 m/s (45mph) • Ensure that motor heat will not affect structure • Manufacturing • 30 units • $300 per unit • $20,000 for start-up • 1 month start-up, 1 month production Research
• Materials
• Resin
• Processing
• Curing Research: Materials
• Glass Fiber
• Carbon Fiber
• Kevlar Glass Fiber
• Pros • Lightweight • Inexpensive • Cons • Heavier than other composites Carbon Fiber
• Pros • Light weight • Very strong • Durable • Cons • Very expensive materialogical.com/wordpress/?cat=7 Kevlar
• Developed by DuPont in 1965
• Pros • Thermal and electric insulator • Absorbs energy • Cons • Breaks down in UV light • Sublimes at 450oC
www.kevlar.com Research: Resin
• Polyester • Inexpensive • Low order crosslinking
• Epoxy • Difficult to use • High order crosslinking
• Vinyl Ester • Compromise • Easy to use Research: Bonding Processes
• Resin Transfer
• Contact Molding
• Vacuum Bag Resin Transfer
• Process • Material held in a closed mold • Resin injected • Pros • Smooth, even sides • Few voids • Cons • Complex molds • Resin rich
• Material and resin are applied with a roller or brush by hand • Pros • Inexpensive • Fast • Cons • Resin rich • Labor • Messy Vacuum Bag Molding
Applies vacuum to hold a part securely to a mold
• Pros • Product is smoother • Controlled fiber and resin ratio • Cons • Time consuming • Materials Possible Curing Processes
• Autoclave – High temperature and pressure
• Oven – High temp
• Room temperature Selection
• Material – Carbon Fiber
• Light weight • Strong • Standard in military MAV construction • Resin – Vinyl Ester • Forgiving catalyst ratio • Strong and tough • Process – Vacuum Infusion • Control resin ratio • Low voids • Molds – Female, Plaster Original Design
• Solid nose
• Main structure with cap
• Four parts
•10 Bonding strips
Design Development
• 4 main parts to 2 main parts
• Flat sheet • 2 Bonding strips • Cap • Simpler • Faster production • More continuous structure and surface Design Development Construction: Molds • Wooden mold box • Acrylic • Wax • Rapid prototyped male mold form • Industrial gypsum plaster • Wax Construction: Fuselage
• Wax • Poly Vinyl Alcohol (PVA) • Carbon Fiber • Peel Ply • Flow Media • Vacuum Bag Bench Test • Run 1 • Run 3 • Full Power for 5 min • 25% for 15 min • No temperature change • No temperature change • Run 2 • 50% for 7 min • No temperature change Impact Testing • Propelled with a pneumatic cannon • Impacted a target ramp at 30o • Speed measurement – Calibration board and semi- high speed camera (120 fps) Impact Results
• With motor • Minimal damage • Motor plate separation • Retained structure • With weight (3 lb total) • Visible damage • Motor plate separation • Retained structure Impact Impact Hiring
• ACMA • Preliminary Contact • Quote Request Package • Detailed description • Detailed drawings • Prototype pictures • Separate package for motor plate Conclusion
• Fuselage Manufacturer –TBD by AFRL
• At least 6 interested companies • Timeline • Production • Motor Plate Manufacturer – Milco Water Jet • Lot Price - $190 ($6.33 per unit) • Timeline - 5 days Recommendations
• Construct parts in house
• Low production numbers • Quality control • Variability • Cost • Research vacuum molding of polymers • Quicker • Less expensive • Compliant parts Summary
• Scope • Design Development
• AFRL Fuselage • Construction Specifications • Testing • Project Specifications • Hiring • Research • Conclusions • Selection • Recommendations • Original Design • Summary • Questions Questions
