Overview of the X-57 Structural Requirements, •

Modifications, and Airworthiness

Wesley Li
[email protected]
Aerostructures Branch
NASA Armstrong Flight Research Center Edwards, CA
 Outline
• X-57 Maxwell Overview
• Structural Design
• Static Structural Analysis and
Airworthiness X-57 Wing
loading
– Mod II 45 lb/ft2

– Mod III
– Mod IV
• Aeroelasticity
Tecnam P2006T
Wing loading
17 lb/ft2
June 17-21, 2019 AIAA Aviation 2019 2
 X-57 Maxwell Overview
Mod SRR Preliminary Design PDR Detailed Design CDR Hardware Fabrication
I
System Integration and testing Flight Testing
•
Complete

II Y15 4Q Y16 4Q Y20 2Q

III Y17 1Q
Y21 3Q
IV Y19 1Q
Mod I Mod II Mod III Mod IV
.....
DEP w ing
deve lopment
and fabricat ion

Ground validation of DEP

Ground and fl ight test Flight test with integrated
validation of electric DEP motors and folding
motors, battery, and props (cruise motors
Flight testing of baseline remain in wing-tips).
instrumentation.
Tecnam P2006T Flight test electric otors relocated
Goals: to wingtips on DEP wing inclu ding Achieves Mod IV (Low-Speed)
Goals:
• Establish Electric Power nacelles {but no DEP motors,
Objectives
• Establish Baseline Tecnam contro ll ers, or fo lding props).
Performance
System Flight Safety
• Pilot Familiarity • Establish Electric Tecnam Achieves Mod III (High- Spiral development process
Retrofit Baseline • Build – Fly – Learn
June 17-21, 2019 AIAA Aviation 2019 Speed) Objectives 3
 X-57 Participating Organizations
TMC Tec hno logies
of West Virgini a
•
NASA Langley: Veh icl e, W ing, Perform ance , Jo by
NASA GRC
Cont ro ls I PTs
NASA Armstrong: Powe r, Inst ru m ent at io n IPTs,
Flight Ops
NASA Glenn: Batt ery Test ing, Therma l!
A nalys is, HL Mot or Cont ro lller
Deve lop m ent (M od IV)
Emp irica l Sys. Aero .: Prim e co nt ractor
Sca led Composit,es : Mod II Int egrat io n (batt eries,
mot o rs, cont ro ll ers, coc kp it )
NASA LaRC
Joby Av iatiion : Mod II Cru i se Motor &
Cont ro ll e r develop ment NASAAFRC Tec nam
Xperimenta l : W ing des ig n and Elect ric
manufact uring Powe r
Syste m s
Elect ric Power Sys.: Ba tt ery deve lop men t
Xpe riment al Sca led
TMC Techno logi,es: Soft wa re V&V Com posit es
Tecna m : Base line COTS ai rfra me
w it ho ut e ng ines
Italy-

June 17-21, 2019 AIAA Aviation 2019 4

 Structural Design/Analysis Roles
• Responsibility:
•
– Provide structural design requirements and airworthiness approach (AFRC)
– Oversight for all structural design/analyses (AFRC & LaRC)
– Conduct airworthiness design reviews (AFRC)
– Support structural ground and flight testing (AFRC)
• AFRC and Flight Safety Review Board have final technical authority
• ESAero is the Prime contractor and has lead role in structural design and analysis
,
Mod II Mod III Mod IV
• Scaled Composite – design, analysis and • Xperimental LLC has lead role in Mod • ESAero - high-lift system (blade, hub and
integration (batteries, motors, III/IV wing design and analyses tail nacelle) structural design and analysis
controllers, cockpit) • Wing IPT (AFRC & LaRC) provides • GRC - heat sink design and analysis
• Joby Aviation - the Cruise Motor verification and oversight for wing • Zone 5/Trust Automation - high-lift motor
structural design and analysis design/analyses and nacelle structures design and analysis

June 17-21, 2019 AIAA Aviation 2019 5

 X-57 Structural Design Criteria
• X-57 Wing will be designed for MTOW 3000 lbs (Tecnam P2006 MTOW is 2712 lbs)
•
– To prevent overloading the wing and fuselage structure, maneuver load factor and landing load factor will be
limited
• The primary structures are designed to meet the X-57 loads requirements
– Mod II: Cruise motor, new motor mount and its supporting structure, battery mount, floor structure,
equipment support structure and fuselage
– Mod III: Composite wing and wing/fuselage attachment
– Mod IV: High-Lift assembly structure
• Aircraft Structural Safety of Flight Guidelines AFRC G-7123.1-001 along with industry standards is
being use as a guideline
– 2.25 FS – for metallic structures if structural design is verified by analysis only
– 3.00 FS – for composite structures if structural design is verified by analysis only (when using well established
composite processes and materials)
– 1.80 FS – for either metallic or composite structure when verified by proof tests to 120% of flight limit loads
• All structure MUST have positive Margin(s) of Safety
June 17-21, 2019 AIAA Aviation 2019 6
 Composite Structures Verification and
Validation (V&V) Process
,
I COMPONENTS I
:,'
•
~
• Building-block approaches for testing and analysis ~, '
ISUB-COMPONENTS I
• Contractors provide their composite cure process, process
,./:~ >.
specification, and process control for AFRC review and approve
• The coupon testing and verification requirements have to
,/IJ
:
I DETAILS I .
- ~ '-.
\._

,: . .' ~
~~~~~
' .'
negotiate with project management regarding risk and budget :' , I ELEMENTS I '

Composite life cycle

:' ~
/~ 1

-- ~
........
------------I
,

--~
From: MIL-HDBK-17-1F (2002)
- --
-~..........
j g~ j
COUPONS I-----------\
'

--~ -- ~
b-~---

--~ \--\,

* Re:::==========:)
Va lid design
Material Design va lue Joint test " Detail" test(s) Build Inspect Test Inspect
Ready for
screen ing Test coupons Eg. Wing/fuselage manufacture
joint

June 17-21, 2019 AIAA Aviation 2019 7

 • Mod II
X-57 Airworthiness Approach
Ultimate Factors of Safety for Mod II
Metallic structures - verified by analysis only 2.25
•
Composite structures - verified by analysis only 3.0
Existing primary and original structures 1.5
Non-primary structures and no structural analysis – verified by proof test N/A

Ultimate Factors of Safety for Mod III Wing

• Mod III Mod III Wing: metallic or composite structure
• Verified by proof tests to 120% of flight limit loads 1.8
• Instrumented for loads monitoring during envelope expansion
Control surface system and linkage: Metallic structures – verified by analysis only 2.25

Ultimate Factors of Safety for Mod IV HL System

• Mod IV Metallic structures if structural design is verified by analysis only
Composite structures - verified by analysis only
2.25
3.0
Hub, Blade retention structures - verified by proof tests to 200% of max centrifugal load. >2.0

June 17-21, 2019 AIAA Aviation 2019 8

 •
X-57 Mod II

Ultimate Factors of Safety for Mod II

Metallic structures - verified by analysis only 2.25
Composite structures - verified by analysis only 3.0
Existing primary and original structures 1.5
Non-primary structures and no structural analysis – verified by proof test N/A
 Mod II Loads Requirements
• Due to the max gross weight increased, Mod II
Critical Load Cases for primary structure

Down, Nz
Design Limit
Load Factor (g)
3.4
Factor of Safety
New metallic
structure
2.25
Exiting
structure
1.5
•
Condition

Maneuver loads
maneuver limit load factor will be reduced and limited Forward, Nx -18 1 1 Crash loads
Sideward, Ny +/-4.5 1 1 Crash loads
to 3.4g Up, Nz -6 1 1 Crash loads

• The primary structures are designed for Design Limit

Factor of Safety
New metallic Exiting Condition
Load Factor (g)
– Flight Maneuver and Ground loads Down, Nz 3.4
structure
2.25
structure
1.5 Maneuver loads
– Emergence landing / Crash Loads: The items of Forward, Nx
Sideward, Ny
-3
-1.33
2.25
2.25
1.5
1.5
Maneuver loads
Maneuver loads
mass within cabin that could injure an occupant, Up, Nz -2 2.25 1.5 Maneuver loads

will be secured to fuselage structure to withstand X-57 Mod II VN Diagram

the 18g cash loads conditions.
• Cruise Motor, Motor Mount and Nacelle/Pylon are
designed for
– Flight Maneuver and Ground loads
– Powerplant loads (Thrust, Torque, P-factor, and
Gyroscopic)

June 17-21, 2019 AIAA Aviation 2019 10

Design Loads
Cruise Motor Design and Analysis
Cruise motor design
•
Cruise motor structure
• Flight maneuver loads
Stator:
• Ground & landing loads AL7075-T6
• Powerplant loads (applied at
the propeller CG Rotor
• Max thrust
Propeller
• Max torque
Mount
• P-factor loads
• Gyroscopic loads
Magnets
Modal analysis: First Bending Mode 154Hz – 9240 RPM

June 17-21, 2019 AIAA Aviation 2019 11

Design Loads
Mod II Motor Mount Design
Motor Mount and Truss FEM Analysis •
Static, Buckling, and Modal analysis
• Flight maneuver loads 4130 Welded
Stress Truss
• Ground & landing loads
• Powerplant loads
• Max thrust
• Max torque
• P-factor loads
• Gyroscopic loads Motor adapter

Motor mount loads calibration test Integration (Top View)

Strain Gages Instrumentation Develop load equation for in-flight
Torque and Thrust measurement

June 17-21, 2019 AIAA Aviation 2019 12

 Design Loads
X-57 Battery Integration
Contactor pallet (left and right) •
• Flight maneuver loads
• Crash loads
BCM

Fwd Battery Mount Aft (Cargo) Battery Mount Battery Venting

Battery Venting
(3” dia)
Hermetically
seals battery
smoke/eject
from cabin
volume

June 17-21, 2019 AIAA Aviation 2019 13

 X-57 Aircraft Modification
Air Data Probe
Secondary Egress •
Adapter
Tube
I:
Bulkhead Fitting
Nose Fit
(Proof test 100%)
Air Data Boom
100600-01

Equipment Pallet (co-pilot seat) Upgraded 4-point harness

Cockpit Display

Per AC21-34 SHOULDER HARNESS - SAFETY BELT

INSTALLATIONS & AC 43.13-2B Ch 9 SHOULDER
HARNESS INSTALLATIONS:
June 17-21, 2019 AIAA Aviation 2019 14
 •
X-57 Mod III
Ultimate Factors of Safety for Mod III Wing
Mod III Wing: metallic or composite structure
• Verified by proof tests to 120% of flight limit loads 1.8
• Instrumented for loads monitoring during envelope expansion
Control surface system and linkage: Metallic structures – verified by analysis only 2.25
 X-57 Wing Design
• Designed and Fabricated by Xperimental
.lfa;11 spar

•
• Composite: semi-monocoque wing From Spar
011, r,or rib for t!nl'h HL 11nc,11,

• Single and continuous main spar:

responsible to carry normal and axial
loads (shear and bending) On, pair off ront ribs for enl'h HL nnu ll,

• Working skin: buckling free and

responsible to carry torsional loads Front Spar
Zshape
RearSpnr
Cshape

• Front and rear spars used to receive

Better Tors1011al box Closes the bock ton1on box
Hard pomt for HL nacelles • Hard poml for bell cranks and mfnon hmges
"Bmf" stnke
Lending edge

external loads (nacelles and controls) Lnpjoint

Cnrl>on Jibn skin witI, U-iin PVC/ oonr

,\ fain Biu d11ct .Mnln Spnr
Cshnp,
Easyfabncanon ofa mono/itJ11c structure
Jnsm11ne111arion duct Pre-Pregfabricarion
From ribs will act as stiffener for wwp deformation
June 17-21, 2019 AIAA Aviation 2019 16
 •
X-57 Wing Loads Analysis
Total 20 load cases
S • 66.67 s. r.
Mod II and IV V-n Diagram (3000 lbs)
X- S7 mod-4 v- n diagr:>m Zl21Rll.iU
\ V • 3000 lb$.

)_,_t; ---------------·-------·-------------
C·Llrf: 1.10
U KEAS
~ 'KEA!
JOJKEAS
•
• Flight loads
– Maneuver load factor (+3.42 / –1.37g)
– Asymmetric thrust at takeoff and at cruise
• Ground loads
• Powerplant loads
-···-·_._
– Max cruise and High-Lift motor thrust and torque
1~-0•-·-
.......... ·-· """'· -··
vc•c.,., .. ~ -
. . . . . .,,.., ..... 1<190-
...,,.
~-
Flap 30'" With Hl Pow, r
(Mod IV)

– P-factor and Gyroscopic loads Case # Airspeed Load fa cto r W eight CG position A lt itude Description
89kEAS (Vs) +1 .0 133S! N 4044.81mm Oft Vs - l g AS L
152kEAS(Vc) +2.9 1 13351 N 4044.81mm Oft Ve max ni due stall ASL
164kEAS(Va) +3.4 2 133S! N 4044.81mm Oft Va - posit ive maneuver ASL
Load application using 190kEAS(Vd) +3.42 13351 N 4044.81mm Oft Vd - pos itive maneuve r ASL
190kEAS(Vd) -1.71 13351 N 4044.81mm Oft Vd - negat ive gust ASL
RBE3 and CFD surface 89kEAS(Vs) +LO 13351 N 4044.81mm 15000ft Vs - l g high alt itude
1S2kEAS(Vc) +2.9 1 133S! N 4044.81mm 15000ft Ve max nz due stall high alt.
Aerodynamic pressure mapped on the 164kEAS(Va) +3.42 13351 N 4044.81mm 15000ft Va - positive maneuver high alt.

loads (wing and wing surface 9

10
190kEAS(Vd )
190kEAS(Vd )
+3 .4 2
-1.71
13351 N
13351 N
4044.81mm
4044.81mm
15000ft
15000ft
Vd - pos itive maneuver high alt.
Vd - negat ive gust high alt .
11 164kEAS(Va) +2.99 4044.81mm Oft Asym - 100/75
control surface 12 164kEAS(Va) +2.28
13351 N
13351 N 4044.81mm Oft Rolling at Va

loads) 13
14
164kEAS(Va)
190kEAS(Vd )
+2.28
+2.28
13351 N
133S! N
4044.81mm
4044.81mm
Oft
Oft
Rolling at Va - max roll rate
Rolling atVd
15 190kEAS(Vd) +2.28 133S! N 4044.81mm Oft Rolling at Vd - max roll rate
16 130kEAS(Vij +2.00 13351 N 4044.81mm Oft Flap

Ca\e # Airs pe e d l oa d Weight CG p osition Ah My

17 164 +2.565 13351N 4044 .8 1mm Oft 1927 376.25
18 164 +3 ,42 13351N 4044 .8 1mm Oft 1400 318.75
19 164 +2.S 13351N 4044 .81mm Oft 1S42 a 261.S 104.6

June 17-21, 2019 AIAA Aviation 2019 17

 •
X-57 Wing Structures Airworthiness Approach
To demonstrate and validate the structural integrity of the wing for flight Pre-test Analysis
•
• Design to 1.8, Proof to 1.2, Full flight instrumentation, Fly to 1.0

Structural Margins Greater

Design Limit Load (DLL) Than or Equal to zero
180%DLL

120%DLL
100%DLL Pre-Test Post-Test
Inspection Inspection
Flight Test Monitoring
(NDI) (NDI) Monitor loads at root

0%DLL
Aero and Inertia Design and
• • Proof Test Flight Test
inboard station

Design Load Analysis and Load and Periodic

FOS = 1.8 Calibration Inspections

June 17-21, 2019 AIAA Aviation 2019 18

 X-57 Wing Testing
• Proof and loads calibration testing
– Will be conducted at AFRC in August 2019
Aileron Bellcrank
Actuator
Cruise Simulator
Loading

X-57 Wing
•
– Qualification test the wing structure to 120% Design
Limit Load (DLL)
– Qualification test cruise motor mount hard points to
120% DLL (axial in-plane)
– Produce a database suitable for deriving wing load
equations by applying a set of known loads and Test Rig
Jacks
recording strain gage outputs
– Verify the control surfaces (flaps and ailerons) are free
of binding while the wings are loaded to 100% DLL.
– Collect wing deflection measurement data for FEM
model comparison and model tuning
• Ground Vibration Test (GVT)
– Wing on proof test fixture
– Identify the structural modes and the associated mode
shapes as well as frequency and damping values of the
wing before the integrated aircraft GVT

June 17-21, 2019 AIAA Aviation 2019 19

 Fuselage Wing Attachment Structural Analysis
• Asymmetric thrust at take-off load case is the critical load
•
Asymmetric Thrust at Take-Off Case

case for the fuselage wing attachment.

• Require new wing attachment and new doubler
• Existing fuselage FS set at 1.5, same as Tecnam FS
• All new hardware FS set at 2.25 (no-test)
Inertia relief boundary conditions
New wing attachment Riveted to sides only Full thrust one side + Half thrust
(14 places) other side + 2.0 x VS 1g ASL
Drilled and tapped
screws using Helicoil®
threaded inserts New
(8 places) Doubler
6.75” 0.08” thick
6.75” long
0.33”
thick
Factors of Safety Materials
0.1”
Existing FS Ult. 1.5 Al 6082-T6 thick
Al 7050
New FS Ult. 2.25 Ftu (psi) 42,000 74,000
June 17-21, 2019 Fuselage Skin 20
No-test FS Fsu (psi) AIAA Aviation 43,000
27,000 2019
 •
X-57 Mod IV
Ultimate Factors of Safety for Mod IV HL System
Metallic structures if structural design is verified by analysis only 2.25
Composite structures - verified by analysis only 3.0
Hub, Blade retention structures - verified by proof tests to 200% of max centrifugal load. >2.0
 Mod IV High Lift Concept Overview
• PDR completed in April, 2019
HL Tail Nacelle
•
• Design Loads (Inertial, Thrust, Torque, Imbalance, P-factor,
Gyroscopic, etc)
• Decoupled from motor operational dwell frequencies:
5460 RPM / 91 Hz.
• To avoid coupling with wing flutter modes

Folding Propellers HL Exploded View

Blades fold back and Structural Model
“stow” onto Nacelle

Long Nacelle FEM

Short Nacelle FEM

June 17-21, 2019 AIAA Aviation 2019 22

 Mod IV Airworthiness Approach
• Design and Analysis
•
– 2.25 FS (for metallic) and 3.0 FS (for composite).
• Hub, Blade Retention, and Counterweight Proof Test - Per 14 CFR 35.35(a)(b)(c) and AC 35-1
– Proof test for a period of one hour to 200% maximum expected centrifugal load at max rpm
operation
• Acceptance Testing
– Each hub, blade retention system, and counterweights: proof test to 120% operational loads
limits for 2 times of a normal flight operation hour (Whirl testing)
– Each motor assembly: proof test to 120% of operational loads limits for 2 times of a normal
flight operation hour
• Endurance/Fatigue Testing
– HL assembly: test for 4 times the expected operation lifespan to the operational loads
• Periodic Inspections during flight operations
June 17-21, 2019 AIAA Aviation 2019 23
 •
Aeroelasticity
 •
Aeroelasticity: Airworthiness Approach
Finite Element Model (FEM) development Component GVT
•
– Structural and Aero models Wing on Proof Test Fixture GVT
• Flutter analyses
– Whirl Flutter: propeller/hub/motor/pylon assembly
mounted to wing Example: Cruise Prop/Hub
GVT on Foam Soft Support
– Classical Vehicle Flutter: Bending/Torsion coupling
• Ground Vibration Test (GVT) to measure natural modes,
frequencies and structural damping
– Correlate structural model for final flutter analyses
Soft Support (Bungee) Design for GVT
– Conduct multiple GVTs (prop & hub, wing on proof
test fixture, wing on fit-check fuselage) to reduce
project risk by not waiting for the integrated aircraft
GVT
• Flight flutter testing for envelope clearance
– Instrumentation distribution on aircraft
Support aircraft Support MLG axles by attaching
– Control room monitoring nose around NG bungee support beams to jacks
June 17-21, 2019 AIAA Aviation 2019 bulkhead 25
 •
Thank You
X-57 Technical Document Portal (https://nasa.gov/x57/technical)