The Manufacturing and Integration of Fluidic Oscillators for Composite Aircraft Structures
Aly, Ahmed A.
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Active flow control (AFC) devices have been proven to reduce drag and delay stall on commercial aircraft. This leads to lower fuel usage and thus reduced flight costs. However, there is a large uncertainty as to how to integrate AFCs into aircraft, specifically those with composite structures. Additionally, the cost of manufacturing AFCs for large scale production has not been previously studied. In this thesis, a design concept for the attachment of a fluidic oscillator (FO) to a composite aircraft structure is investigated. A systematic approach from the conceptual design to the final design is performed using different design tools. Axiomatic Design is first used to generate the functional requirements and design parameters. Following that, morphological charts are used to generate conceptual designs. These designs are then compared to select the top design from each category through the use of a sensitivity analysis and design of experiments. A final design is created with both CAD and physical models. Design validation of the final model is conducted using finite element analysis and mold simulations. A cost analysis is performed to select the most cost-effective design configuration based on large volume FO production. Through the design validation and cost estimation, the final design is shown to be feasible for large volume manufacturing.