P16121: SAE Aero Aircraft Design & Build
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Build & Test Prep

Table of Contents

Team Vision for Build & Test Prep Phase

The intent of this phase was to perform all tasks necessary to be ready to start manufacturing and perform tests after week two. In order to achieve this readiness, members of the team came back to RIT during winter break to optimize and address issues related to structural design. The main focus of this was to better locate the center of gravity to the designed location, and to justify the integrity of the main gear during landing impact. To this point, the team is ahead of schedule, looking at the proposed schedule. All materials have been ordered, aluminum parts have been sent to the Brinkman Lab for water jet cutting, the static thrust test fixture has been repaired, and test plans have been created.

This document summarizes all of the work done during winter break and through Week 1 of MSD II: P16121 MSD II Winter Break - Week 1 Summary

This document summarizes all of the work done during Week 2 of MSD II: P16121 MSD II Week 2 Summary

The following images display the aircraft after structural design and center of gravity optimization.

Aircraft After Winter Break Optimization

Aircraft After Winter Break Optimization

View of Center of Gravity Location on Aircraft

View of Center of Gravity Location on Aircraft

Detailed View of Center of Gravity Location

Detailed View of Center of Gravity Location

Here is the resultant Bill of Materials:

P16121 Bill of Materials

Test Plan Summary

The following link leads to test plans the team will utilize when performing tests, during, and at the end of, the manufacturing process. Note that these test plans are developed to ensure all engineering requirements are met, which have been based off of the SAE Aero Design rules.

P16121 Requirements and Testing Plans

Risk and Problem Tracking

Ensuring the structural integrity of the main landing gear during landing impact has been an ongoing problem that has been addressed by performing Explicit Dynamics impact simulation using ANSYS Workbench. This has resulted in a moderate risk when it comes to the structural integrity of the entire aircraft, as simulation shows stresses past the yield strength of materials used. The landing gear have been redesigned to accommodate larger bearing areas through bearing plates and to ensure no bearing surfaces are in contact with bolt threads. We have also refined the simulation parameters. Previous worse case scenario testing did not represent an achievable situation. The new parameters, while relaxed, represent a more reasonable understanding of what a 'worst case' might be. Below are documents and images displaying current problem tracking and risk analysis.

P16121 Problem Tracking Document

P16121 Build & Test Prep Risk Assessment

Impact Stress Analysis Overall Results

Impact Stress Analysis Overall Results

Impact Stress Analysis Displaying Max Stress

Impact Stress Analysis Displaying Max Stress

Initial Main Landing Gear Design

Initial Main Landing Gear Design

Revised Main Landing Gear Design

Revised Main Landing Gear Design

Plans for next phase

Observing the schedule, by the next phase, the team will have completed the thrust and electrical systems test, all remaining components will be ordered, and the fuselage, wing box, and wings, will be midway in their build.

P16121 MSD II Schedule

P16121 MSD II Schedule

P16121 MSD II Schedule as .xlsx or .pdf

Individual contributions are as follows:

Marc

Dom

Matt

Chris

Ron


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