High Aspect Ratio Composite Wings: Geometrically Nonlinear Aeroelasticity, Multi-Disciplinary Design Optimization, Manufacturing, and Experimental Testing

In the field of aerospace engineering, the design and manufacturing of high aspect ratio composite wings has become a focal point of innovation and efficiency. These long, slender wings, constructed with advanced materials such as carbon fiber and employing efficient manufacturing methods such as vacuum bagging, hold the promise of significantly lighter aircraft, reduced fuel consumption, and enhanced overall performance. However, to fully realize these benefits, it is imperative to address a multitude of structural and aeroelastic constraints. This research presents a novel aeroelastically tailored Multi-objective, Multi-disciplinary Design Optimization (MMDO) approach that seamlessly integrates numerical optimization techniques to minimize weight and ensure structural integrity. The optimized wing configuration is then manufactured, and a Ground Vibration Test (GVT) and static deflection analysis using the Digital Image Correlation (DIC) system are used to validate and correlate with the numerical model. Within the fully automated in-house Nonlinear Aeroelastic Simulation Software (NAS2) package (version v1.0), the integration of analytical tools offers a robust numerical approach for enhancing aeroelastic and structural performance in the design of composite wings. Nonlinear aeroelastic analyses and tailoring are included, and a population-based stochastic optimization is used to determine the optimum design within NAS2. These analytical tools contribute to a comprehensive and efficient methodology for designing composite wings with improved aeroelastic and structural characteristics. This comprehensive methodology aims to produce composite wings that not only meet rigorous safety and performance standards but also drive cost-efficiency in the aerospace industry. Through this multidisciplinary approach, the authors seek to underscore the pivotal role of tailoring aeroelastic solutions in the advanced design and manufacturing of high aspect ratio composite wings, thereby contributing to the continued evolution of aerospace technology.