Numerical Investigation and Optimization of a Morphing Airfoil Designed for Lower Reynolds Number

A novel concept of morphing airfoils, capable of changing camber and thickness, is proposed. A variable airfoil shape, defined by six input parameters, is achieved by allowing the three spinal points (at fixed axial positions) to slide vertically, while the upper and lower surfaces are determined by the lengths of the three corresponding ribs that are perpendicular to the spine. Thus, it is possible to find the most appropriate geometric configuration for a wide range of possible operating conditions often present with contemporary unmanned aerial vehicles. Shape optimizations for different Reynolds numbers and different cost functions are performed by coupling a genetic algorithm with simple panel method flow calculations. The obtained airfoils are presented and compared, whereas the proposed concept is validated by more advanced flow simulations. It appears that improvements in aerodynamic performance of nearly 20% can be expected at Re ranging from 0.05 × 10⁶ to 0.1 × 10⁶. The proposed methodology shows promise and can be applied to different types of lifting surfaces, including wing, tail or propeller blade segments. To check the viability of this method for producing airfoils that can be used in a practical sense, structural analysis of one of the obtained geometries using a simplified 1D finite element method as well as a more detailed 3D analysis are performed. The model is then 3D-printed on a fused deposition modeling (FDM) printer with a polyethylene terephthalate glycol (PETG) filament, and the capability of the airfoil to adequately morph between the two desired geometries is experimentally shown.