NLFFD

NLF Starboard Leading Edge & Top cover design & manufacturing Trials

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 Obiettivo del progetto (Objective)

'The Natural Laminar Flow (NLF) aerofoil is a potential key technology for the next generation of aircraft, improving the performance by reducing drag, and hence reducing emissions.

The requirements of a NLF wing differ significantly from a conventional turbulent wing, requiring changes to both the wing architecture, aerofoil definition and the detailed design and manufacturing concepts. The performance of a NLF wing requires very tight surface roughness and waviness tolerances and contamination free surfaces in the areas where laminar flow is to be maintained. NLF wings also require alternative Leading Edge (LE) moveable concepts, novel LE/Wing-box joints, and slender LE sections.

This proposal is for the design of the starboard LE and Upper cover for a NLF Wing flight demonstrator. The current baseline solution is a metallic LE and composite Top Cover. The LE and Top cover will be joined to a wing-box (outside of scope) and attached to the flight test demonstrator which will be an A340, with the outer third of a starboard wing (from Rib 28 to wingtip) replaced.

The demonstrator aims to validate that a jointed wing concept (LE Top cover) can be manufactured in realistic high rate and repeatable conditions appropriate to a civil short range aircraft to the required level of aerodynamic surface quality to achieve laminar flow.

From experience on existing Clean Sky Smart Fixed Wing Aircraft (SFWA) calls, current LE and Top Cover design and manufacture capability, and thorough investigation into the Call, GKN recognise the very demanding tolerance and hence manufacturing requirements to achieve a successful demonstrator outcome.

It is understood that any proposed solutions, for LE or Top Cover design, must be developed and proved to such a level that the components can obtain flight clearance for test. GKN believe that ‘traditional’ wing manufacture and assembly techniques will be unable to achieve the required tolerances at an acceptable cost, and therefore novel techniques and concepts will need to be investigated.'

Introduzione (Teaser)

Airplane wings exploit airflow to provide the lift that makes flight possible. Next-generation laminar flow technology will soon be showcased in a technology demonstrator that puts the EU ahead of the pack in green air transport concepts.

Descrizione progetto (Article)

Cutting edge design concepts are now focused on decreasing turbulence for improved performance, lower fuel consumption and reduced emissions. The natural laminar flow (NLF) airfoil is a key enabling technology for the next generation of greener aircraft. It is expected to bring a 10 to 15 % increase in fuel efficiency with a corresponding reduction in emissions. It will also secure and expand Europe's share of this valuable market sector for the next 30 to 40 years.

To achieve NLF, the wing must meet very tight restrictions on surface roughness, waviness and free-surface contamination. These restrictions impose important challenges on design and manufacturing. The EU-funded project 'NLF starboard leading edge & top cover design & manufacture' (NLFFD) aims to meet aerospace requirements on a jointed wing concept. The leading edge (LE) and top cover for an NLF wing flight demonstrator needs to be consistently manufactured at a suitably high production rate.

Building on extensive and highly productive design and manufacturing tool and process development work, the small-scale demonstrator program was successfully completed. Scientists are now finishing mid-scale manufacture. Minor tool modifications and the design of additional fixtures based on results of the previous phase will aid in completion and testing. Tooling for the final full-scale demonstrator is underway.

Achievement of a flying technology demonstrator of the LE and top cover of an NLF wing should facilitate adoption of NLF technology. As the world is pressed to adopt greener air transport concepts, the race for widespread implementation in commercial aircraft is on. NLFFD intends to place the EU firmly in the lead at this critical time to secure important benefits for the EU economy and its citizens.