Structural Analysis and Experimental Tests of a Morphing-Flap Scaled Model

The implementation of morphing wing mechanisms shows significant potential for improving aircraft performance, as highlighted in the recent literature. The Clean Sky 2 AirGreen 2 European project team is currently performing ground and wind tunnel tests to validate improvements in morphing wing structures. The project aims to demonstrate the effectiveness of these morphing designs on a full-scale flying prototype. This article describes the design methodology and structural testing of a scaled morphing-flap structure, which can adapt to three different morphing modes for various flight conditions: low-speed (take-off and landing) and high-speed (cruise). A scale factor of 1:3 was selected for the wind tunnel test campaign. Due to challenges in scaling the embedded mechanisms and actuators necessary for shape-changing, a full geometrical scale of the real flap prototype was not feasible. Static analyses were performed using the finite element method to address critical load conditions determined through three-dimensional computational fluid dynamic (CFD) analysis. The finite element (FE) analysis was conducted and the results were compared with the empirical data from the structural test. Good correlations were found between the structural testing results and numerical predictions, including static deflections and elastic deformations under applied loads. This indicates that the modeling approaches used during the design and testing phases were highly successful. Based on simulations for the ultimate load conditions tested during the wind tunnel tests, the scaled flap prototype has been deemed suitable for further testing.