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PEMP

ACD2505

Airfoil Design

Session delivered by:


Prof M.
Prof. M D.
D Deshpande

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Session Objectives
-- At the end of this session the delegate would have
understood
• The airfoil design procedure
• Inverse design procedure
• Design
D i off speciali l airfoils
i f il like
lik High
Hi h lift,
lift Laminar,
L i
Transonic, Low Re, Low moment airfoils
• Multiple
u p e design
des g point
po airfoils
a o s
• Trailing edge flaps and leading edge devices

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S i Topics
Session T i
1. Airfoil Design Methods
2. Inverse Design
3. Thick Airfoil Design
4. High Lift Airfoil Design
5. Laminar Airfoil Design
6
6. Transonic Airfoil Design
7. Low Reynolds number Airfoil Design
8. Low Moment Airfoil Design
9. Multiple Design Point Airfoils
10. High Lift Systems and Trailing Edge Flaps
11
11. Leading Edge Devices

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Airfoil Design

This chapter is an introduction to the problem of airfoil


design. Some typical design goals and constraints are
discussed,
d scussed, aalong
o gwwith a bbrief
e ddiscussion
scuss o oof des
design
g
methodology.

Design Methods and Objectives


Some Typical Design Problems
Hi h Lift S
High Systems
t
References

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Airfoil Design Methods

The process of airfoil design proceeds from a knowledge of the


boundary layer properties and the relation between geometry
and pressure distribution. The goal of an airfoil design varies.
Some airfoils are designed to produce low drag (and may not be
required to generate lift at all.) Some sections may need to
produce low drag while producing a given amount of lift. In
some cases, the drag doesn't really matter -- it is maximum lift
that is important. The section may be required to achieve this
performance with a constraint on thickness, or pitching moment,
or off-design performance, or other unusual constraints. Some
of these are discussed further in the section on historical
examples .

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Ai f il Design
Airfoil D i Methods
M h d

One approach to airfoil design is to use an airfoil that was


already designed by someone who knew what he or she was
doing This "design
doing. design by authority"
authority works well when the goals of
a particular design problem happen to coincide with the goals of
the original airfoil design. This is rarely the case, although
sometimes
i existing
i i airfoils
i f il are goodd enough.h In
I these
h cases,
airfoils may be chosen from catalogs such as Abbott and von
Doenhoff's Theory y of Wingg Sections, Althaus' and Wortmann's
Stuttgarter Profilkatalog, Althaus' Low Reynolds Number
Airfoil catalog, or Selig's "Airfoils at Low Speeds".

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The advantage
Th d to this
hi approachh is
i that
h there
h isi test data
d
available. No surprises, such as a unexpected early stall, are
likely.
y On the other hand,, available tools are now sufficiently
y
refined that one can be reasonably sure that the predicted
performance can be achieved. The use of "designer airfoils"
specifically tailored to the needs of a given project is now very
common. This section of the notes deals with the process of
custom airfoil design.

Methods for airfoil design can be classified into two categories:


direct and inverse design.
g

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Direct Methods for Airfoil Design


The direct airfoil design methods involve the specification of a
section geometry and the calculation of pressures and performance.
Onee ev
O evaluates
u es thee ggiven
ve sshape
pe andd then
e modifies
od es thee shape
s pe too
improve the performance.

The two main sub-problems


sub problems in this type of method are
1. the identification of the measure of performance
2. the approach to changing the shape so that the performance is
improved

The simplest
p form of direct airfoil design
g involves startingg with an
assumed airfoil shape (such as a NACA airfoil), determining the
characteristic of this section that is most problematic, and fixing this
problem
problem.

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This process of fixing the most obvious problems with a given


airfoil is repeated until there is no major problem with the
section.
ti The
Th design
d i off suchh airfoils,
i f il does
d nott require
i a specific
ifi
definition of a scalar objective function, but it does require some
expertise to identify the potential problems and often
considerable expertise to fix them. Let's look at a simple (but
real life!) example.

A company is in the business of building rigid wing hang


gliders and because of the low speed requirements, they decide
t use a version
to i off one off Bob
B b Liebeck's
Li b k' very high
hi h lift airfoils.
i f il

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Here is the pressure distribution at a lift coefficient of 1.426.


1 426
Note that only a small amount of trailing edge separation is
predicted. Actually, the airfoil works quite well, achieving a
Clmax off almost
l t 1.9
1 9 att a Reynolds
R ld numberb off one million.
illi

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This glider
Thi lid was actuallyll built
b il andd flown.
fl It,
I ini fact,
f won the
h
1989 U.S. National Championships. But it had terrible high
speed
p performance.
p At lower lift coefficients the wingg seemed to
fall out of the sky. The plot below shows the pressure
distribution at a Cl of 0.6. The pressure peak on the lower
surface causes separation and severely limits the maximum
speed. This is not too hard to fix.

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By reducing
B d i the h lower
l surface
f "bump"
"b " near the
h leading
l di edged andd
increasing the lower surface thickness aft of the bump, the pressure
ppeak at low Cl is easilyy removed. The lower surface flow is now
attached, and remains attached down to a Cl of about 0.2. We must
check to see that we have not hurt the Clmax too much.

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Here is the new section at the original design condition (still less
than Clmax).) The modification of the lower surface has not done
much to the upper surface pressure peak here and the Clmax turns
out to be changed very little. This section is a much better match
for the application and demonstrates how effective small
modifications to existing sections can be. The new version of
the gglider did not use this section,, but one that was designed
g
from scratch with lower drag.

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Sometimes the objective of airfoil design can be stated more
positively than,
than "fix
fix the worst things
things". We might try to reduce
the drag at high speeds while trying to keep the maximum CL
greater than a certain value. This could involve slowly
i
increasing
i the
th amountt off laminar
l i flow
fl att low
l Cl's
' and d checking
h ki
to see the effect on the maximum lift. The objective may be
defined numerically. We could actually minimize Cd with a
constraint on Clmax. We could maximize L/D or Cl1.5/Cd [for
Max endurance] or Clmax / Cd at Cldesign.

The selection of the figure of merit for airfoil sections is quite


important and generally cannot be done without considering the
rest of the airplane.
airplane For example,
e ample if wee wish
ish to build
b ild an airplane
with maximum L/D we do not build a section with maximum
L/D because the section Cl for best Cl/Cd is different from the
airplane CL for best CL/CD. [Re-write this awkward sentence].
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Inverse Design

Another type of objective function is the target pressure


distribution. It is sometimes possible to specify a desired Cp
distribution and use the least squares difference between the
actual and target Cp's as the objective.
objective This is the basic idea
behind a variety of methods for inverse design. As an example,
thin airfoil theory can be used to solve for the shape of the
camberline that produces a specified pressure difference on an
airfoil in potential flow.

The second part of the design problem starts when one has
somehow defined an objective for the airfoil design.

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Inverse Design (Contd)

This stage of the design involves changing the airfoil shape to


improve the performance. This may be done in several ways:

11. By hand,
hand using knowledge of the effects of geometry
changes on Cp and Cp changes on performance.

2. By numerical optimization, using shape functions to


represent the airfoil geometry and letting the computer decide
on the sequence of modifications needed to improve the design.

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Typical Airfoil Design Problems

Regardless of the design goals and constraints, one is faced with


some common problems that make airfoil design difficult. This
section deals with the common issues that arise in the following
design problems:

ƒ Design for maximum thickness


ƒ Design for maximum lift
ƒ Laminar boundary layer airfoil design
ƒ High lift or thickness transonic design
ƒ Low Reynolds number airfoil design
ƒ Low or positive pitching moment designs
ƒ Multiple design points

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Thi k Airfoil
Thick Ai f il Design
D i

The difficulty with thick airfoils is that the minimum pressure is


decreased ( that means more negative) due to thickness. This
results in a more severe adverse pressure gradient and the need
to start recovery sooner. If the maximum thickness point is
specified, the section with maximum thickness must recover
f
from a given
i point
i with
i h the
h steepest possible
ibl gradient.
di This
Thi is
i
just the sort of problem addressed by Liebeck in connection
with maximum lift. The thickest ppossible section has a boundaryy
layer just on the verge of separation throughout the recovery.

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The thickest
Th hi k sectioni at
Re = 10 million is 57%
thick,, but of course,, it
will separate suddenly
with any angle of
attack.
attack

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High Lift Airfoil Design


To produce high lift coefficients, we require very negative
pressures on the upper surface of the airfoil. The limit to this
suction may be associated with compressibility effects, or may
be imposed by the requirement that the boundary layer be
capable of negotiating the resulting adverse pressure recovery.
recovery It
may be shown that to maximize lift starting from a specified
recovery height and location, it is best to keep the boundary
layer on the verge of separation*. Such distributions are shown
below for a Re of 5 million. Note the difference between
laminar and turbulent results.
* This conclusion, described by Liebeck, is easily derived if
Stratford's criterion or the laminar boundary layer method of Thwaites
is used.
used For other turbulent boundary layer criteria
criteria, the conclusion is
not at all obvious and is almost surely not generally valid.
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The thickest
Th hi k section i at ReR = 10 million
illi is
i 57% thick,
hi k but
b off
course, it will separate suddenly with any angle of attack.

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For maximum
F i airfoil
i f il lift,
lif the
h best
b recovery location
l i is
i chosen
h
and the airfoil is made very thin so that the lower surface
pproduces maximum lift as well. (Since
( the upper
pp surface Cp is
specified, increasing thickness only reduces the lower surface
pressures.)

Well, almost. If the upper surface Cp is more negative than -3.0,


the perturbation velocity is greater than freestream, which
means, for
f a thin
hi section,
i the h lower
l surface
f flow
fl isi upstream.
This would cause separation and the maximum lift is achieved
with an upper
pp surface velocityy just
j over 2U and a bit of
thickness to keep the lower surface near stagnation pressure.

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A more detailed
discussion of this topic
may be found in the
section on high lift
systems.
t

Recall: Cp = 1 - U2/U∞2

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Laminar Airfoil Design

As discussed in the section on boundary layers, laminar flow


may be useful for reducing skin friction drag, increasing
maximum lift, or reducing heat transfer. It may be achieved
without too much work at low Reynolds numbers by
maintaining a smooth surface and using an airfoil with a
favorable pressure gradient. The section below shows how the
pressures may be tailored to achieve long runs of laminar flow
on upper and/or lower surfaces.

Again, the Stratford-like pressure recovery is helpful in


achieving the maximum run of favourable gradient on either
upper or lower surfaces.
surfaces

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Transonic Airfoil Design

The transonic airfoil design problem arises because we wish to


limit shock drag losses at a given transonic speed. This
effectively limits the minimum pressure coefficient that can be
tolerated. Since both lift and thickness reduce ((increase in
magnitude) the minimum Cp, the transonic design problem is to
create an airfoil section with high lift and/or thickness without
causing strong shock waves.
waves One can generally tolerate some
supersonic flow without drag increase, so that most sections can
operate efficiently as "supercritical airfoils". A rule of thumb is
that the maximum local Mach numbers should not exceed about
1.2 to 1.3 on a well-designed supercritical airfoil. This produces a
considerable increase in available Cl compared
p with entirelyy
subcritical designs.
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Supercritical
S i i l sections
i usually
ll refer
f to a special
i l type off airfoil
i f il
that is designed to operate efficiently with substantial regions of
supersonic
p flow. Such sections often take advantage
g of many y of
the following design ideas to maximize lift or thickness at a
given Mach number:

ƒ Carry as much lift as is practical on the aft potion of the


section where the flow is subsonic. The aft lower surface is an
obvious
b i candidate
did for
f increased
i d loading
l di (more
( positive
i i Cp), )
although several considerations discussed below limit the extent
to which this approach
pp can be used.
ƒ Make sure that sufficient lift is carried on the forward portion
of the upper surface. As the Mach number increases, the
pressure peak near the nose is diminished and without additional
blunting of the nose, possible extra lift will be lost in this region.
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• The
Th lower
l surface
f near the
h nose can also l be
b loaded
l d d by
b
reducing the lower surface thickness near the leading edge. This
pprovides both lift and ppositive ppitchingg moment.
• Shocks on the upper surface near the leading edge produce
much less wave drag than shocks aft of the airfoil crest and it is
feasible although not always best,
feasible, best to design sections with
forward shocks. Such sections are known as "peaky" airfoils and
were used on many transport aircraft.
• The
Th idea
id off carefully
f ll tailoring
il i the h section
i to obtain
b i locally
l ll
supersonic flow without shockwaves (shock-free sections) has
been ppursued for manyy yyears, and such sections have been
designed and tested. For most practical cases with a range of
design CL and Mach number, sections with weak shocks are
favored
favored.

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One must bbe cautious


O i with
i h supercritical
i i l airfoil
i f il design.
d i Several
S l
of these sections have looked promising initially, but led to
pproblems when actuallyy incorporated
p into an aircraft design.
g
Typical difficulties include the following.

• Too much aft loading can produce large negative pitching


moments with trim drag and structural weight penalties.
• The adverse pressure gradient on the aft lower surface can
produce
d separation
i ini extreme cases.
• The thin trailing edge may be difficult to manufacture.
• Supercritical,
p and especially
p y shock-free designs
g often are very
y
sensitive to Mach and CL and may perform poorly at off-design
conditions. The appearance of "drag creep" is quite common, a
situation in which substantial section drag increase with Mach
number occurs even at speeds below the design value.
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The section with pressures shown below is typical of a modern


supercritical
i i l section
i with
i h a weakk shock
h k at its
i design
d i condition.
di i
Note the rooftop Cp design with the minimum Cp considerably
ggreater above Cp*.

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A Little Digression
g & Recapitulation
p

Drag of Bodies

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Flow around a Cylinder

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Flow around a Cylinder and Sphere

Length Effect

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Flow around nearly 2-D Bodies

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Drag of 2-D Bodies at Re = 10 5 ACD2505

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Drag of Axisymmetric Bodies

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Drag of 3-D Bodies at Re = 10 5 ACD2505

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Drag of 3-D Bodies at Re = 10 (… contd.) 5

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Viscosity, and hence Reynolds number, strongly affects the


performance of wings and airfoils, making it an important
parameter
t tot match
t h in
i wind
i d tunnel
t l tests.
t t It is
i often
ft nott possible
ibl
to match these dimensionless parameters precisely.

The next plot shows the effect of Reynolds number on


maximum lift to drag ratio for two dimensional airfoil sections.
Note the plight of insects.
insects

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Maximum Lift-Drag Ratio.


Ratio
Q: There are five items in this graph. Compare carefully their
relative L/D (max) values, keeping in mind their Re values.

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The plot here shows the effect of Reynolds number on the


maximum section lift coefficient of a few typical airfoil
sections. Note that these are not necessarily the best sections for
hi h lift,
high lift though.
th h

Recent studies have shown that substantial changes in CLmax are


seen even at quite high Reynolds numbers, making it difficult to
extrapolate data on small wind tunnel models.

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Maximum Lift
Compare carefully the CL (max) values with the respective L/D
(max) values from the previous figure.

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Low Reynolds Number Airfoil Design

Low Reynolds numbers make the problem of airfoil design


difficult because the boundary layer is much less capable of
handling an adverse pressure gradient without separation. Thus,
very low Reynolds number designs do not have severe pressure
gradients and the maximum lift capability is restricted.

Low Reynolds number airfoil designs are cursed with the


problem of too much laminar flow. It is sometimes difficult to
assure that the boundary layer is turbulent over the steepest
pressure recovery regions. Laminar separation bubbles are
common and unless properly stabilized can lead to excessive
ddragg and
d low
ow maximumu lift..

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At very low Reynolds numbers, most or all of the boundary


layer is laminar. Under such conditions the boundary layer can
handle only gradual pressure recovery. Based on the expressions
for laminar separation, one finds that an all-laminar section can
generate a CL of about 0.4 or achieve a thickness of about 7.5%.
(Try this with a simple airfoil design code such as PANDA.)

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L M
Low Momentt Airfoil
Ai f il Design
D i

When the airfoil pitching moment is constrained, it is not always


possible to carry lift as far back on the airfoil as desired. Such
situations arise in the design of sections for tailless aircraft,
aircraft
helicopter rotor blades, and even sails, kites, and giant
pterosaurs. The airfoil shown here is a Liebeck section designed
t perform
to f well
ll att low
l Reynolds
R ld numbers
b with ith a positive
iti Cm0.
Its performance is not bad, but it is clearly inferior in Clmax when
compared to other sections without a Cm constraint. (Clmax a =
1.35 vs. 1.60 for conventional sections at Re = 500,000.)

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Multiple Design Point Airfoils


One of the difficulties in designing a good airfoil is the
requirement for acceptable off-design performance. While a
very low
l drag
d section
ti isi nott too
t hard
h d to
t design,
d i it may separate t
at angles of attack slightly away from its design point. Airfoils
with high lift capability may perform very poorly at lower
angles of attack.

One can approach the design of airfoil sections with multiple


design points in a well-defined way. Often it is clear that the
upper surface will be critical at one of the points and we can
design the upper
pper surface
s rface at this condition.
condition The lower
lo er surface
s rface can
then be designed to make the section behave properly at the
second point. Similarly, constraints such as Cm0 are most
effected by airfoil trailing edge geometry
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When such a compromise is not possible, variable geometry can


be employed (at some expense) as in the case of high lift
systems.

Transonic
section at a
range of
CL's, from
Drela.
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Hi h Lift S
High Systems
t

A wingg designed
g for efficient high-speed
g p flight
g is often qquite
different from one designed solely for take-off and landing.
Take-off and landing distances are strongly influenced by
aircraft stalling speed,
speed with lower stall speeds requiring lower
acceleration or deceleration and correspondingly shorter field
lengths. It is always possible to reduce stall speed by increasing
wing
i area, butb t it is
i nott desirable
d i bl to t cruise
i with ith hundreds
h d d off
square feet of extra wing area (and the associated weight and
drag), area that is only needed for a few minutes. Since the
stalling speed is related to wing parameters by:

Vstall 1/2
t ll = (2 W / (S ρ CL max))

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It is also possible to reduce stalling speed by reducing weight,


weight
increasing air density, or increasing wing CLmax . The latter
parameter is the most interesting. One can design a wing airfoil
that compromises cruise efficiency to obtain a good CLmax , but
it is usually more efficient to include movable leading and/or
trailingg edges
g so that one mayy obtain ggood highg speed
p
performance while achieving a high CLmax at take-off and
landing. The primary goal of a high lift system is a high CLmax;
however it may also be desirable to maintain low drag at take-
however, take
off, or high drag on approach. It is also necessary to do this with
a system that has low weight and high reliability.

This is generally achieved by incorporating some form of


trailingg edge
g flap
p and pperhaps
p a leading
g edge
g device such as a
slat.
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Trailing edge flaps

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Th ttriple-slotted
The i l l tt d flap
fl system
t used
d on a 737

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A double
double-slotted
slotted flap and slat system (a 4-element
4 element airfoil) is
shown below. Here, some of the increase in CLmax is associated
with an increase in chord length (Fowler motion) provided by
motion along the flap track or by a rotation axis that is located
below the wing.

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Modern high lift systems are often quite complex with many
elements and multi-bar linkages. Here is a double-slotted flap
system as used on a DC-8. For some time Douglas resisted the
temptation to use tracks and resorted to such elaborate 4-bar
linkages. The idea was that these would be more reliable. In
practice,, it seems both schemes are veryy reliable.
p

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Current practice has


been to simplify the
flap system and
double (or even
single) slotted
systems are often
preferred.
f d
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Flaps change the airfoil pressure distribution,


distribution increasing the
camber of the airfoil and allowing more of the lift to be carried
over the rear portion of the section. If the maximum lift
coefficient is controlled by the height of the forward suction
peak, the flap permits more lift for a given peak height. Slotted
flaps
p achieve higher
g lift coefficients than plain
p or split
p flaps
p
because the boundary layer that forms over the flap starts at the
flap leading edge and is "healthier" than it would have been if it
had traversed the entire forward part of the airfoil before
reaching the flap. The forward segment also achieves a higher
Clmax than it would without the flap because the pressure at the
trailing edge is reduced due to interference, and this reduces the
adverse pressure gradient in this region.

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The favorable effects of a slotted flap on Clmax was known early


in the development on high lift systems. That a 2-slotted flap is
better than a single-slotted flap and that a triple-slotted flap
achieved even higher Cl's suggests that one might try more
slots. Handley Page did this in the 1920's.
Tests showed a Clmax of almost 4.0 for a 6-slotted airfoil.

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A remarkably high Clmax of almost 4.0


4 0 is achieved for a 6-
6
slotted airfoil. An increased number of slats decreases Clmax .

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Leading edge devices

Leading edge devices such as nose flaps, Kruger flaps, and slats
reduce the pressure peak near the nose by changing the nose
camber. Slots and slats permit a new boundary layer to start on
the main wingg pportion,, eliminating
g the detrimental effect of the
initial adverse gradient.

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Leading edge devices

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Today computational fluid dynamics is used to design these


complex
l systems; however,
h the
h prediction
di i off CLmax by
b direct
di
computation is still difficult and unreliable. Wind tunnel tests
are also difficult to interpret
p due to the sensitivityy of CLmax to
Reynolds number and even freestream turbulence levels.

N-SS computations of the flow over a 4-element


N 4 element airfoil section(NASA)

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Summary

The following topics were dealt in this session

• Airfoil design procedure


• Inverse design procedure
• Design of special airfoils like High lift, Laminar,
Transonic, Low Re, Low moment airfoils
• Multiple design point airfoils
• Trailing edge flaps and leading edge devices

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Thank you

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