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Design, Build, Fly: The Angry Bird

The goal of this project was to design an aircraft that could perform specific manuevers and meet confitions within a certain time frame.
Skills
  • XFLR5
  • MatLab
  • OnShape
  • Arduino
  • Mechanical Aptitude
Timeline
April - June 2024 10 Weeks
Collaborators
This task was done with a team of 6 students, including myself

Defining a Problem

To design an optimal aircraft, we first needed to thoroughly understand the various maneuvers and specifications the aircraft must be capable of performing. We were tasked with designing a plane that can fly the following tasks with and without a payload.
  • The aircraft needed to achieve takeoff within a 25-foot distance.
  • The aircraft could not exceed a weight of 10 lbs with payload.
  • Aircraft had to land on the runway
  • The Aircraft must complete 3 DBF laps within a 5 minute flight window (10 minutes with payload).
Click Here to see all of the rules

Choosing the Airfoil

  • To choose the best airfoil, the team split up to analyze four options: NACA 4412, 2412, SD7062, and Clark Y. I focused on the Clark Y, which we ultimately selected.
  • For reliable data:
  • I used XFLR5 to analyze the lift-to-drag ratio.
  • In MATLAB, I tested different chord lengths and wingspans to determine the foil's maximum weight capacity.
With a 12 inch chord, a 48 inch wingspan, and the motor we were required to use (Xing 2204), we calculated that the plane could be a total weight of 7lbs.

The Design Process

After our team selected an airfoil, I was assigned the task of designing the empennage. To optimize the aircraft's performance, I ensured the horizontal stabilizer achieved a horizontal tail volume coefficient of 0.40 and the vertical stabilizer attained a vertical tail volume coefficient of 0.03. I then designed a fuselage in such a way to allow a payload to be inserted at the quarter chord. This would ensure that the stability of the aircraft does not falter when adding the payload.

Assembly

To make the aircraft without the payload as light as possible, we used a mix of balsa wood and polyfilm as the two main components. The balsa wood mainly made up the frame of the different aircraft components and polyfilm was thermoformed over the frame to create a smooth and strong exterior.
I was tasked with assembling the empennage. After constructing the frame and thermoforming the polyfilm, I faced a challenge: How can I effectively operate the rudder and elevator with a servomotor while preserving the tail's aerodynamic integrity?
To solve this, I made precise incisions in the plastic to fit a servo motor and a wooden plate, which I glued to the inner frame. I connected a metal rod from the servo to a joint on the elevator, using the same approach for the vertical stabilizer, and it functioned optimally.
After completing the empennage, I assisted my teammates with the wing assembly. I applied the same servo strategy I had used earlier to control the flaps effectively. It was time to assemble the entire aircraft. The fuselage housed the motherboard and provided space for the payload. Wires were carefully arranged to minimize drag, and the motor was securely installed. With everything in place, the plane was ready for flight!

Results

  • Our aircraft went above and beyond the required maneuvers. The aircraft (which we named the Angry Bird) did the following:
  • Took off right at the 25 foot mark
  • Performed 3 DBF laps
  • Landed back on the runway
  • Performed all tasks in under 5 minutes
  • Did a loop maneuver (We did this for fun)

Takeaways

  • Learned how to use XFLR 5
  • Strengthened my CAD skills
  • Enhanced my MatLab abilities
  • Further developed my Arduino skills
  • Fortified by leadership skills
  • Boosted my teamwork skills
  • Learned the fundamentals of aircraft design
  • Had an amazing time

Additional Images

“Aviation is proof that given the will, we have the capacity to achieve the impossible.”

— Eddie Rickenbacker