Degree Fyp Thesis

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AIRFRAME DESIGN AND MANUFACTURE OF

ULTRALIGHT FUSELAGE

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““I declared that this thesis is the result of my I declared that this thesis is the result of my own work except the ideas andown work except the ideas and summaries which I have declared their sources. The

summaries which I have declared their sources. The thesis has not been accepted forthesis has not been accepted for any degree and is not concurrently submitted in candidature of any degree. “ any degree and is not concurrently submitted in candidature of any degree. “

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““I declared that I read this tI declared that I read this thesis and in my point of view this thesis is qualified in termhesis and in my point of view this thesis is qualified in term of scope and quality for the purpose of awarding the Bachelor of Engineering (Hons) of scope and quality for the purpose of awarding the Bachelor of Engineering (Hons)

Mechanical. “ Mechanical. “

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AIRFRAME DESIGN AND MANUFACTURE OF ULTRALIGHT FUSELAGE AIRFRAME DESIGN AND MANUFACTURE OF ULTRALIGHT FUSELAGE

MOHD ZAIREN BIN MOHAMMAD ZIN MOHD ZAIREN BIN MOHAMMAD ZIN

(2009848424) (2009848424)

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ACKNOWLEDGEMENT ACKNOWLEDGEMENT

In the name of Allah, Most Gracious, Most Merciful. In the name of Allah, Most Gracious, Most Merciful.

I wish to appreciate my supervisor, Prof. Dr. Ir. Wahyu Kuntjoro for giving much of I wish to appreciate my supervisor, Prof. Dr. Ir. Wahyu Kuntjoro for giving much of hishis time and experience throughout the project from beginning until the end. I am very time and experience throughout the project from beginning until the end. I am very

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ABSTRACT ABSTRACT

Ultralight aircraft airframe is an extremely lightweight aircraft and categorized as Ultralight aircraft airframe is an extremely lightweight aircraft and categorized as an experimental aircraft by Federal Aviation Regulations (FAR). FAR 103 states that an experimental aircraft by Federal Aviation Regulations (FAR). FAR 103 states that the ultralight airframe design is less than

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TABLE OF CONTENTS TABLE OF CONTENTS ACKNOWLED ACKNOWLEDGEMENT GEMENT ... i... i ABSTRACT ABSTRACT ... ii... ii LIS

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2.6

2.6 Finite Element Method ... 16Finite Element Method ... 16 2.7

2.7 Material Material Strength Strength ... ... 1818 CHAPTER

CHAPTER 3: 3: METHODOLOGY METHODOLOGY ... .... 2121 3.1

3.1 Introductions ... 23Introductions ... 23 3.2

3.2 Visit Malacca 4B Flying Club ... 23Visit Malacca 4B Flying Club ... 23 3.3

3.3 Material Source ... 24Material Source ... 24 3.4

3.4 Preliminary Design... 25Preliminary Design... 25 3.5

3.5 Fuselage Design ... 27Fuselage Design ... 27 3.6

3.6 Manufacturing Process ... 28Manufacturing Process ... 28 3.7

3.7 Material Testing ... 40Material Testing ... 40 3.8

3.8 Finite Element Analysis of Finite Element Analysis of Fuselage Airframe Fuselage Airframe ... 44... 44 3.9

3.9 Fuselage Structure Test ... 47Fuselage Structure Test ... 47 3.10

3.10 Assembly of Airfra Assembly of Airframe me ... 4... 499 CHAPTER

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LIST OF FIGURES: LIST OF FIGURES:

Figure 2.1: Ultraligh

Figure 2.1: Ultralight Quicksilver MX Sprint [15] t Quicksilver MX Sprint [15] ... .... 66 Figure 2.2: Fuselage Ai

Figure 2.2: Fuselage Airframe Design [16] rframe Design [16] ... ... 88 Figure 2.3: BWB Baseline II-E2 UAV airframe model [6]

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Figure 3.12: Sample of square cutoff

Figure 3.12: Sample of square cutoff from 33mm tube aluminium hollow ...from 33mm tube aluminium hollow ... .. 3030 Figure 3.13: Hydraul

Figure 3.13: Hydraulic Swing Beam Sheariic Swing Beam Shearing Machine...ng Machine... ... .... 3030 Figure 3.14: The plate for differen

Figure 3.14: The plate for different joints of the trike t joints of the trike ... ... 3131 Figure 3.15: Using

Figure 3.15: Using Drilling MachinDrilling Machine for e for drillindrilling process g process of joints of joints ... 31... 31

Figure 3.16: Precision Lathe Machine ... 32

Figure 3.17: Threading the shaft ... 32

Figure 3.18: Shaft of rare wheel assembly along with dipole joint Figure 3.18: Shaft of rare wheel assembly along with dipole joint ... ... 3333 Figure 3.19: Rare Left side of Trike Joints... 33

Figure 3.19: Rare Left side of Trike Joints... 33

Figure 3.20: The bendin Figure 3.20: The bending process of seat frame g process of seat frame ... 34... 34

Figure 3.21: Seat assembly process ... 34

Figure 3.22: Front trike joint ... 35

Figure 3.23: Trike assembly ... 35

Figure 3.24: Foot Paddle ... 36

Figure 3.25: Nose plate of Trike ... 36

Figure 3.26: Grinding process for most edges of Figure 3.26: Grinding process for most edges of the airframe the airframe ... . 3737 Figure 3.27: Assembly of front wheel at Trike nose Figure 3.27: Assembly of front wheel at Trike nose ... 37... 37 Figure 3.28: F

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Figure 4.4: Deformation of Airframe at 3.8g ... 58

Figure 4.5: Plot Results for maximum Stress at 3.8g ... 58

Figure 4.6: Deformation of Airframe at 2.5g ... 59

Figure 4.7: Plot Results for maximum Stress at 2.5g ... 59

Figure 4.8: Deformation of Airframe at 1g ... 60

Figure 4.9: Plot Results for maximum Stress at 1g ... 60

Figure 6.1: Trike Part Design ... 78

Figure 6. Figure 6.2: Trike Joint Design ... 792: Trike Joint Design ... 79

Figure 6.3: Trike Nose Design ... 80

Figure 6.4: Trike Part Design ... 80

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LIST OF TABLES: LIST OF TABLES:

Table 2.1: Lift Force Based on BWB Area Percentage ... 17 Table 2.1: Lift Force Based on BWB Area Percentage ... 17 Table 2.2:

Table 2.2: Weight PercenWeight Percentage tage ... . 1717 Table 2.3: Distribution of Weight ... 17 Table 2.3: Distribution of Weight ... 17

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LIST OF

LIST OF ABBREABBREVIATION:VIATION:

BWB

BWB Blended Wing Blended Wing BodyBody CFD

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LIST OF SYMBOLS: LIST OF SYMBOLS:

Ag

Ag SilverSilver

Al

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Li Lithium

L

Lll LengthLength

n

n Load Load FactorFactor

Mg Magnesium Mg Magnesium Mn Manganese Mn Manganese Na Sodium Na Sodium Ni Nickel Ni Nickel P Phosphorus P Phosphorus Pb Lead Pb Lead Si Silicon Si Silicon Sn Tin Sn Tin

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CHAPTER 1: CHAPTER 1:

INTRODUCTION INTRODUCTION

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1.1

1.1 Background Background of of studystudy

Ultralight is defined as extreme light weight

Ultralight is defined as extreme light weight airplaneairplane. Airframe is . Airframe is defined as thedefined as the body of an aircraft as distinct from its engine. Ultralight airframe is the body of an body of an aircraft as distinct from its engine. Ultralight airframe is the body of an aircraft at minimum weight without consideration of its engine. The

aircraft at minimum weight without consideration of its engine. The project produces theproject produces the result of strength requirement or static

result of strength requirement or static behavior of the ultralight airframe fuselage part.behavior of the ultralight airframe fuselage part.

The fuselage of the

The fuselage of the ultralight airframe has several sections included with theultralight airframe has several sections included with the connections to other important section

connections to other important sections such as the wing. Is such as the wing. I t consists both trike andt consists both trike and empennage compo

empennage components. The trike is the part of the nents. The trike is the part of the cockpit where the pilot is. It is cockpit where the pilot is. It is aa main component used for installation

main component used for installations of other part such as s of other part such as the front wings, thethe front wings, the empennage, the power plant (engine and fuel compartment) and the controls of the empennage, the power plant (engine and fuel compartment) and the controls of the airframe. The study is done as such in consideration of all the loadings applied at those airframe. The study is done as such in consideration of all the loadings applied at those parts of the fuselage where the airframe is static.

parts of the fuselage where the airframe is static.

Ultralight airframe design gives further understandin

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standard given to determine the safety feature of

standard given to determine the safety feature of the airframe design of the fthe airframe design of the fuselage ofuselage of the ultralight aircraft as it is the main body for the whole product.

the ultralight aircraft as it is the main body for the whole product.

1.2

1.2 Problem Problem StatementStatement

Design of ultralight airframe fuselage deals with the safety

Design of ultralight airframe fuselage deals with the safety consideraconsideration in usetion in use during aviation purpose. It could bring harm to

during aviation purpose. It could bring harm to the user and public without properthe user and public without proper analysis done on the airframe structure. There are several reports considering the analysis done on the airframe structure. There are several reports considering the safety of the structure is not valid. 13

safety of the structure is not valid. 13thth March 2010, a March 2010, a 54-year-old ultraligh54-year-old ultralight pilott pilot

(Antares) was severely injured during an accident in Chugiak, Alaska where there was (Antares) was severely injured during an accident in Chugiak, Alaska where there was evidence of in-flight airframe failure [11]. This proves t

evidence of in-flight airframe failure [11]. This proves t hat the structure of hat the structure of the ultralightthe ultralight airframe can fail anytime without pr

airframe can fail anytime without pr ior to the ior to the user’s knowleduser’s knowledge. Therefore, it ge. Therefore, it isis mandatory to check the safety of airframe design of ultralight aircraft of the trike to mandatory to check the safety of airframe design of ultralight aircraft of the trike to minimize the damage.

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1.4

1.4 Scope Scope of of ProjectProject

The study is done by adopting the design of existing ultralight fuselage airframe, The study is done by adopting the design of existing ultralight fuselage airframe, the Quicksilver MX 2S design. It

the Quicksilver MX 2S design. It is also to is also to consider the regulations establisheconsider the regulations established for thed for the type of aircraft. This is done based on the airframe selection and its static behavior. type of aircraft. This is done based on the airframe selection and its static behavior. The material strength is tested

The material strength is tested by sparking test, bending test by sparking test, bending test and tensile test. Analysisand tensile test. Analysis can be done by

can be done by implementinimplementing Finite Element Method for g Finite Element Method for the fuselage of the the fuselage of the ultralightultralight airframe.

airframe.

1.5

1.5 Significance Significance of of ProjectProject

The importance of this project is to give out more understanding for the The importance of this project is to give out more understanding for the ultralight airframe in this country. The airframe itself is important in terms of the ultralight airframe in this country. The airframe itself is important in terms of the

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LITERATURE REVIEW LITERATURE REVIEW

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Figure 2.1: Ultralight Quicksilver MX Sprint [15] Figure 2.1: Ultralight Quicksilver MX Sprint [15]

Ultralight is identified as a ve

Ultralight is identified as a vehicle not aircraft. hicle not aircraft. Because they are vehBecause they are vehicles andicles and not aircraft, this

not aircraft, this regulation allowregulation allows individuals to s individuals to operate ultralight vehicles withoutoperate ultralight vehicles without

requiring FAA pilot or vehicle certification. Upon publishing Part 103 the FAA said it did requiring FAA pilot or vehicle certification. Upon publishing Part 103 the FAA said it did not wish to

not wish to issue pilot certificates for ultralight operators. FAA understood individualsissue pilot certificates for ultralight operators. FAA understood individuals who want to

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2.2

2.2 Ultralight Ultralight RegulationsRegulations

There are several types of

There are several types of regulations needed to be considered before buildinregulations needed to be considered before buildingg the airframe of the

the airframe of the ultralight which determineultralight which determines the expected and limitations of s the expected and limitations of thethe specifications of the airframe. The first

specifications of the airframe. The first important part of the regulations is from important part of the regulations is from thethe airframe weight. One of the

airframe weight. One of the regulations is the Federal Aviation Regulations (FAR) [4]regulations is the Federal Aviation Regulations (FAR) [4] (Page 23).

(Page 23).

There are several parts within the

There are several parts within the regulation. The basic part is the regulation. The basic part is the FAR23 forFAR23 for determining the minimum takeoff weight. Ultralight is an experimental aircraft within the determining the minimum takeoff weight. Ultralight is an experimental aircraft within the special category but the airworthiness certificate can be deducted as

special category but the airworthiness certificate can be deducted as a normal categorya normal category aircraft [11].The regulation states as follows:

aircraft [11].The regulation states as follows:



 The Maximum Takeoff Weight; normal, utility or acrobatic category ≤The Maximum Takeoff Weight; normal, utility or acrobatic category ≤ 5670kg.5670kg. 

 The The Maximum Maximum TakeoTakeoff Weight; commuter category ≤ ff Weight; commuter category ≤ 8618kg8618kg..

Ultralight also has its own unique regulations within the FAR. Ultralight is within the Ultralight also has its own unique regulations within the FAR. Ultralight is within the

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(4) Has a power-off stall speed which does not exceed 44.5 km/h calibrated airspeed. (4) Has a power-off stall speed which does not exceed 44.5 km/h calibrated airspeed.

103.3 Inspection

103.3 Inspection requirements.requirements. (a) Any person operating an ultralight vehicle under this

(a) Any person operating an ultralight vehicle under this part shall, upon request, allowpart shall, upon request, allow the Administrator, or his designee, to

the Administrator, or his designee, to inspect the vehicle to determine the applicabilityinspect the vehicle to determine the applicability of this part.

of this part. (b) The pilot

(b) The pilot or operator of an ultralight vehicle must, upon ror operator of an ultralight vehicle must, upon r equest of the Administrator,equest of the Administrator, furnish satisfactory evidence that the vehicle is subject

furnish satisfactory evidence that the vehicle is subject only to the provisions of tonly to the provisions of thishis part.

part.

103.5 Waivers. 103.5 Waivers.

No person may conduct operations that require a deviation from this part except under No person may conduct operations that require a deviation from this part except under a written waiver issued by the

a written waiver issued by the AdministratoAdministrator.r.

103.7 Certification and registration. 103.7 Certification and registration.

(a) Notwithstanding any other section pertaining to certification of aircraft or

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The design of the fuselage is considered along with the positions of each The design of the fuselage is considered along with the positions of each component of the airframe within the fuselage. It is also where the position of the pilot component of the airframe within the fuselage. It is also where the position of the pilot is located as to initiate the controls of the

is located as to initiate the controls of the aircraft along the rest of the airframe partsaircraft along the rest of the airframe parts design of the aircraft such

design of the aircraft such as the positioning of the as the positioning of the wingspan, the engine or powerwingspan, the engine or power plant, pilots and passengers seats, the empennage and back wings. It is an important plant, pilots and passengers seats, the empennage and back wings. It is an important part within the airframe of

part within the airframe of every aircraft design as the design requires theevery aircraft design as the design requires the

determination of the center of gravity for the whole airframe [9] (Chapter 5, page 86). determination of the center of gravity for the whole airframe [9] (Chapter 5, page 86).

There are several examples of fuselage design such as the Unmanned Aerial There are several examples of fuselage design such as the Unmanned Aerial Vehicle (UAV) at Universiti Teknologi MARA (UiTM) which is a

Vehicle (UAV) at Universiti Teknologi MARA (UiTM) which is a radio controlled aircraftradio controlled aircraft called “Kenyalang” of the conduct a research titled Unmanned A

called “Kenyalang” of the conduct a research titled Unmanned Aerial Vehicle with Fuelerial Vehicle with Fuel Cell Propulsion System. The airframe is designed based on balsawood rib with

Cell Propulsion System. The airframe is designed based on balsawood rib with aluminium framewo

aluminium framework that rk that holds the engine, fuel cell, hydrogen tank, remote control,holds the engine, fuel cell, hydrogen tank, remote control, instrumentation and landing gear position; and the fuselage is carbon fiber laminated. instrumentation and landing gear position; and the fuselage is carbon fiber laminated.

Other example is based on

Other example is based on the Blended Wing Body (BWB) Baseline I1-E2the Blended Wing Body (BWB) Baseline I1-E2 Unmanned Aerial Vehicle (UAV). This UAV relates to the combination of both the Unmanned Aerial Vehicle (UAV). This UAV relates to the combination of both the

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development of Blended Wing Body concept. This research is in correlation to the development of Blended Wing Body concept. This research is in correlation to the Unmanned Aerial Vehicle (UAV). Using the fundamentals of fluid mechanics, 0.3 Mach Unmanned Aerial Vehicle (UAV). Using the fundamentals of fluid mechanics, 0.3 Mach number of the BWB model can be analyze with Computational Fluid Dynamics (CFD) number of the BWB model can be analyze with Computational Fluid Dynamics (CFD) to various elevator

to various elevator deflection sequencedeflection sequence..

Finite Element Model of the BWB is designed using ANSys software, the same Finite Element Model of the BWB is designed using ANSys software, the same software applying the CFD function, to do

software applying the CFD function, to do the structural analysis. Without elevatorthe structural analysis. Without elevator deflection, it is tested through wind tunnel analysis of 0.1 Mach number for the wing deflection, it is tested through wind tunnel analysis of 0.1 Mach number for the wing pressure distribution

pressure distribution. This . This is done to confirm tis done to confirm t he reliability of CFD and wind tunnel test.he reliability of CFD and wind tunnel test. BWB design sets the pressure drag as crucial to the total drag compared to

BWB design sets the pressure drag as crucial to the total drag compared to

conventional designs due to intrinsic nature of lower surface to volume ratio of the conventional designs due to intrinsic nature of lower surface to volume ratio of the BWB shape [6].

BWB shape [6].

2.4

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2.4.1 The wing structure 2.4.1 The wing structure

Microlight possesses flex wings that have complex wing structure than Microlight possesses flex wings that have complex wing structure than convention

conventional wing. The al wing. The leading edges for the wing primary structure leading edges for the wing primary structure with twowith two segmented tubes of 4.5-5.5m long are joined together at the nose to the keel tube segmented tubes of 4.5-5.5m long are joined together at the nose to the keel tube extended from the trailing edge as shown in Figure 2.4 that runs the length of the wing. extended from the trailing edge as shown in Figure 2.4 that runs the length of the wing. The wing cover seen as a fabric is made from a

The wing cover seen as a fabric is made from a polyester Dacronpolyester Dacron, a high , a high strength non-strength non-porous fabric which is overextended at the wingspan like a sail.

porous fabric which is overextended at the wingspan like a sail. During rigging, the rigidity and form

During rigging, the rigidity and form are ensured by cross tubes that are ensured by cross tubes that are beingare being hinged to each other overhead the keel

hinged to each other overhead the keel tube and half-span of the tube and half-span of the leading edges at theleading edges at the center where the structure is applied considerable internal loads. The form of the wings center where the structure is applied considerable internal loads. The form of the wings is formed based on the tensioning cable where it runs throughout the length of the keel. is formed based on the tensioning cable where it runs throughout the length of the keel. The above statement can be identified using the following Figure 2.5.

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Based on Figure 2.4, the end view of the wing shows an A-frame that have a Based on Figure 2.4, the end view of the wing shows an A-frame that have a basebar and two uprights which are clearly demonstrated in Figure 2.5. The basebar basebar and two uprights which are clearly demonstrated in Figure 2.5. The basebar plays a vital role in flight control giving the roll and pitch control during normal flight. It is plays a vital role in flight control giving the roll and pitch control during normal flight. It is also the principal structure of supporting the tension via flying cables and wires the also the principal structure of supporting the tension via flying cables and wires the wing loads outboard of the leading edge and cross-tube junction. The most part that is wing loads outboard of the leading edge and cross-tube junction. The most part that is compressed is the A-frame uprights and the

compressed is the A-frame uprights and the leading edge of the inboard sections. Theleading edge of the inboard sections. The ideal location of then basebar is critical as it aids in the correct control of the airplane ideal location of then basebar is critical as it aids in the correct control of the airplane where some may refer to it as the ‘piano

where some may refer to it as the ‘piano--playing position’.playing position’. Adjusting the pos

Adjusting the position of the basebaition of the basebar during wir during wing developmeng development is done usuant is done usuallylly through the adjustment of the front rear wires located at nose to the end of the

through the adjustment of the front rear wires located at nose to the end of the basebarbasebar as displayed in Figure 2.5. T

as displayed in Figure 2.5. These wires are fundamentally important for weight shiftinghese wires are fundamentally important for weight shifting the wings against the structure of the aircraft as it locates the base bar and provides the wings against the structure of the aircraft as it locates the base bar and provides maneuvering for wing pitch control. Structural wires are 20-60mm away jointed maneuvering for wing pitch control. Structural wires are 20-60mm away jointed together as parallel wires to provide more clasps for

together as parallel wires to provide more clasps for the form and shape of the form and shape of the aircraft.the aircraft. Different than those lines function are the

Different than those lines function are the luff lines which yield small amount ofluff lines which yield small amount of actual load in flight although aerodynamically crucial to the system. Therefore,

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The wingspan is 8 to 10 meters long and the length of the leading edge or nose The wingspan is 8 to 10 meters long and the length of the leading edge or nose till the trailing edge is 3 meters long. The wing is weight shifted with no tail

till the trailing edge is 3 meters long. The wing is weight shifted with no tail of horizontalof horizontal or vertical stabilizer as any normal airplanes. The trike is hanged to the wings directly or vertical stabilizer as any normal airplanes. The trike is hanged to the wings directly along with the crew, power plant and undercarriage which are gripped by the hang along with the crew, power plant and undercarriage which are gripped by the hang point with a joint of all three axes free degree of freedom to f

point with a joint of all three axes free degree of freedom to f reely rotate in pitch and rollreely rotate in pitch and roll without interference. The joint is fundamentally stable with no pendular stability but without interference. The joint is fundamentally stable with no pendular stability but provided longitudinal stability.

provided longitudinal stability.

The arrangement of the twist of the wing between root and tip,

The arrangement of the twist of the wing between root and tip, the reflex that isthe reflex that is at the inboard trailing edge shaped as an inverted airfoil and the wing sweep gives the at the inboard trailing edge shaped as an inverted airfoil and the wing sweep gives the longitudina

longitudinal stability that is behind the center of gravity (CG). It l stability that is behind the center of gravity (CG). It gives the down force atgives the down force at the wingtips. The minimized washout rods known as tip

the wingtips. The minimized washout rods known as tip sticks are cantilever rodssticks are cantilever rods connected through the leading edge perpendicularly from beneath the wing edge connected through the leading edge perpendicularly from beneath the wing edge supports the sail of t

supports the sail of t he wing that tends to he wing that tends to smoothen out during high speed operation ofsmoothen out during high speed operation of the aircraft.

the aircraft.

The sail tendency to f

The sail tendency to f latten causes the decreasing in static stability which islatten causes the decreasing in static stability which is intolerable affecting loss in longitudinal stabili

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Figure 2.7: Trike

Figure 2.7: Trike structurestructure

Monopole is the bone structure and most vital part of the trike where it holds up Monopole is the bone structure and most vital part of the trike where it holds up the main wheels to the hang point vertically as a pole. All the parts such as wing, power the main wheels to the hang point vertically as a pole. All the parts such as wing, power plant, main wheels and the seat are joined at the structure of monopole. The monopole plant, main wheels and the seat are joined at the structure of monopole. The monopole is set up

is set up so that it so that it can withstand dire stress failure such from fcan withstand dire stress failure such from f atigue crack propagationatigue crack propagation.. The design also includes cable at the center of the monopole itself to provide safety The design also includes cable at the center of the monopole itself to provide safety precautions towards the design that

precautions towards the design that connects the engine mount connects the engine mount or undercarriageor undercarriage connections to the hang point.

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2.5

2.5 Maneuvering Maneuvering Control Control SystemSystem

The maneuvering system consists of several parts which hold onto the The maneuvering system consists of several parts which hold onto the positioning control in-plane and height. There

positioning control in-plane and height. There are several control features for are several control features for ultralightultralight which have 3 axes of motions. There are the elevator motion, rudder motion, and which have 3 axes of motions. There are the elevator motion, rudder motion, and ailerons motion. These parts are crucial for

ailerons motion. These parts are crucial for the airframe to be the airframe to be able to produce motionable to produce motion airborne and for taking off

airborne and for taking off [1] (page 230). The [1] (page 230). The parts produce the following motions:parts produce the following motions:



 Elevator Elevator MotionMotion

o

o Climbing/descendingClimbing/descending o

o PitchingPitching



 Rudder Rudder MotionMotion

o

o Side Side slipping/Skidslipping/Skiddingding o

o YawingYawing



 Ailerons Ailerons MotionMotion

o

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Using motion of control directly from the

Using motion of control directly from the control yokecontrol yoke 1.

1. Controls Controls the the elevator elevator for for up up and and down down motionmotion 2.

2. Controls Controls the the ailerons ailerons for for rotational rotational motionsmotions b) Horizontal motion

b) Horizontal motion

The motion for the rudder is based on footwork which moves left when the left foot is The motion for the rudder is based on footwork which moves left when the left foot is pressed and moves right when the

pressed and moves right when the right foot is pressed.right foot is pressed.

2.6

2.6 Finite Finite Element Element MethodMethod

Using Finite Element Analysis, the analysis for static

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modules area. The following table shows the distribution of weight and lift force with modules area. The following table shows the distribution of weight and lift force with respect to BWB modules area [6].

respect to BWB modules area [6].

Table 2.1: Lift Force Based on BWB Area Percentage Table 2.1: Lift Force Based on BWB Area Percentage

Table 2.2: Weight

Table 2.2: Weight PercentagePercentage

Table 2.3: Distribution of Weight Table 2.3: Distribution of Weight

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BWB Static Results is shown by the resultant BWB stress tensor and BWB Static Results is shown by the resultant BWB stress tensor and displacemen

displacement contour. It t contour. It was found that the was found that the maximum stress value is 81.1 MPa at maximum stress value is 81.1 MPa at nodenode 238, and the maximum displacement value is 156.0 mm at node 1463. The maximum 238, and the maximum displacement value is 156.0 mm at node 1463. The maximum stress occurs at the point connection between wing body and canard modules. The stress occurs at the point connection between wing body and canard modules. The maximum displace

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Table 2.4: Aluminium

Table 2.4: Aluminium Alloy Properties ComparisonAlloy Properties Comparison Aluminium Al

Aluminium Alloy Properties loy Properties 6063-T6 6063-T6 7075-T67075-T6 Ultimate

Ultimate Tensile Tensile Strength Strength 241 241 MPa MPa 572 572 MPaMPa Tensile

Tensile Yield Yield Strength Strength 214 214 MPa MPa 503 503 MPaMPa Modulus

Modulus of of Elasticity Elasticity 68.9 68.9 GPa GPa 71.7 71.7 GPaGPa

Density 2.7g/cc 2.81g/cc

Poisson’s Ratio

Poisson’s Ratio 0.33 0.33 0.330.33

The Stress-Strain relationship allows the identification of mechanical properties such as The Stress-Strain relationship allows the identification of mechanical properties such as the yield strength and modulus of

the yield strength and modulus of elasticity. The following figure shows a stress-strainelasticity. The following figure shows a stress-strain curve.

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1: True elastic limit 1: True elastic limit 2: Proportionality limit 2: Proportionality limit 3: Elastic limit

3: Elastic limit

4: Offset yield strength 4: Offset yield strength

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METHODOLOGY METHODOLOGY

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3.1 Introductions 3.1 Introductions

In this project, several processes have been carried out and were included in In this project, several processes have been carried out and were included in the research methodology

the research methodology. The . The processes consist of the study on processes consist of the study on the structure ofthe structure of airframe fuselage, build the airframe, conduct the test

airframe fuselage, build the airframe, conduct the test analysis and gain data, henceanalysis and gain data, hence compare with the theoretical and the actual value of the adopted design of the ultralight compare with the theoretical and the actual value of the adopted design of the ultralight airframe.

airframe.

3.2

3.2 Visit Visit Malacca Malacca 4B 4B Flying Flying ClubClub

During the duration of the

During the duration of the project, the flying club for project, the flying club for ultralighultralight in t in Batu Berendam,Batu Berendam, Melaka has been visited to carry out actual process of understanding the mechanism Melaka has been visited to carry out actual process of understanding the mechanism built for the airframe of the aircraft.

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Figure 3.2: MX Sport 2S in

Figure 3.2: MX Sport 2S in MelakaMelaka

The preliminary design is set up to be the same model, the Quicksilver MX The preliminary design is set up to be the same model, the Quicksilver MX Sport 2S. The design of the fuselage is tampered to be a single seated instead of a Sport 2S. The design of the fuselage is tampered to be a single seated instead of a double seated aircraft. The entire dimension is obtained by measuring the design using double seated aircraft. The entire dimension is obtained by measuring the design using measuring tape.

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Figure 3.4: Measurement of Material Figure 3.4: Measurement of Material



 Aluminium Aluminium hollow hollow tube tube availableavailable 

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(42)

Figure 3.8: top view of design Figure 3.8: top view of design

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Figure 3.10: Disc Cutting

Figure 3.10: Disc Cutting MachineMachine

The material is based on type 26mm and 33mm hollow tubes. The following figure The material is based on type 26mm and 33mm hollow tubes. The following figure shows the materials cut.

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Figure 3.12: Sample of square cutoff from 33mm tube aluminium hollow Figure 3.12: Sample of square cutoff from 33mm tube aluminium hollow The figure shows the sample needed to

The figure shows the sample needed to be tested through sparking test at be tested through sparking test at the foundrythe foundry lab to obtain the chemical composition data sheet allowing identifying which grade the lab to obtain the chemical composition data sheet allowing identifying which grade the material belongs to.

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Figure 3.14: The plate for different joints of

Figure 3.14: The plate for different joints of the trikethe trike

The hollow beam of each joint is then drilled respective to the length of the hole of each The hollow beam of each joint is then drilled respective to the length of the hole of each joint.

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Figure 3.16: Precision Lathe Machine Figure 3.16: Precision Lathe Machine The result of the lathe process is then threaded out to provide an up

The result of the lathe process is then threaded out to provide an up thread for thethread for the shaft to be bolted together to fix

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Figure 3.18: Shaft of rare wheel assembly along with dipole Figure 3.18: Shaft of rare wheel assembly along with dipole jointjoint The figure shows that the joint for rare dipole and the shaft of rare wheel is being The figure shows that the joint for rare dipole and the shaft of rare wheel is being assembled together to provide strong connection in and out of

assembled together to provide strong connection in and out of the tube. The tthe tube. The tube itselfube itself is 33mm hollow of 1.37

is 33mm hollow of 1.37 thicknesses. By inserting the shaft, the thicknesses. By inserting the shaft, the joint is reinforced andjoint is reinforced and less distortion can occur at the point as the plate of t

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Figure 3.20: The bending process of seat frame Figure 3.20: The bending process of seat frame

The seat frame is then assembled and connected together with the seat as shown in The seat frame is then assembled and connected together with the seat as shown in the Figure 3.21.

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Figure 3.22: Front trike joint Figure 3.22: Front trike joint

The trike structure can be fully assembled as shown in the following Figure 3.23. The trike structure can be fully assembled as shown in the following Figure 3.23.

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Figure 3.24: Foot Paddle Figure 3.24: Foot Paddle The front or nose of the trike

The front or nose of the trike is then plated together to from a platform for the supportis then plated together to from a platform for the support of the front wheels. It is designed base on the latter Quicksilver MX 2 Sprint visited at of the front wheels. It is designed base on the latter Quicksilver MX 2 Sprint visited at Melaka airport.

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Figure 3.26: Grinding process for most edges of the

Figure 3.26: Grinding process for most edges of the airframeairframe

The plate is drilled to produce a hole of diameter 34mm to provide shaft hole for the The plate is drilled to produce a hole of diameter 34mm to provide shaft hole for the support of the wheel along for maneuvering purpose of the wheel to rotate. The front support of the wheel along for maneuvering purpose of the wheel to rotate. The front wheel support is done simply by bending of plate and welded together to a shaft. The wheel support is done simply by bending of plate and welded together to a shaft. The smooth rotation is provided by the installed ‘burger bearing’ that functions solely as a smooth rotation is provided by the installed ‘burger bearing’ that functions solely as a bearing on two plate surfaces.

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Figure 3.28: Front view of trike Figure 3.28: Front view of trike Tie rods Tie rods

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Figure 3.30: Preliminary stage Trike Figure 3.30: Preliminary stage Trike

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3.7

3.7 Material Material TestingTesting

The structure of the airframe needed to be tested in terms of material strength. The structure of the airframe needed to be tested in terms of material strength. Several test such as

Several test such as sparking test, bending test and tensile test sparking test, bending test and tensile test were conducted towere conducted to evaluate the aluminium strength in terms of the Modulus of Elasticity and Yield evaluate the aluminium strength in terms of the Modulus of Elasticity and Yield Strength.

Strength.

3.7.1

3.7.1 Sparking Sparking TestTest

The analysis of the fuselage can be done using the ANSys software. Before the The analysis of the fuselage can be done using the ANSys software. Before the analysis can be done, testing to

analysis can be done, testing to determine the material properties is carried out. Thedetermine the material properties is carried out. The purpose of the testing is

purpose of the testing is originated to identify the strength of toriginated to identify the strength of t he material used basedhe material used based on standards given. The first

on standards given. The first is to identify which category the is to identify which category the material belongs to andmaterial belongs to and the chemical composition. A short test for sparking is done based on sample in Figure the chemical composition. A short test for sparking is done based on sample in Figure 3.12.

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This test is

This test is operated using simple mechanism withooperated using simple mechanism without accordance to any otherut accordance to any other standard. The bending test is carried out

standard. The bending test is carried out to search for the to search for the value of Modulus of Elasticityvalue of Modulus of Elasticity for the hollow beam.

for the hollow beam.

Figure 3.33: Simple Bending Test Configuration Figure 3.33: Simple Bending Test Configuration

Figure 3.33 displays the set-up of simple apparatus which includes the clamp to fix the Figure 3.33 displays the set-up of simple apparatus which includes the clamp to fix the

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Figure 3.35: Deflection of 33mm hollow beam Figure 3.35: Deflection of 33mm hollow beam The result of the test is

The result of the test is recorded on the piece of paper and all measurements. Therecorded on the piece of paper and all measurements. The experiment is repeated to get a

experiment is repeated to get a more accurate value of the more accurate value of the reading.reading. Length, l Length, l Deflection, v Deflection, v Load, 40.05N Load, 40.05N

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Figure 3.37: Specimen of

Figure 3.37: Specimen of 26mm Tube26mm Tube

The samples are tested out in to the machine and the results are based on the input The samples are tested out in to the machine and the results are based on the input key of dimension for each cutoff sample. The dimension of the sample is based on the key of dimension for each cutoff sample. The dimension of the sample is based on the European Standard EN 10002-1: 2001. The dimension is as follows:

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The cross-section area, Al =

The cross-section area, Al = 0.0000179950.000017995 The sample was tested and

The sample was tested and resulted as follows.resulted as follows.

Figure 3.39: Tensile Sample Test after Run Figure 3.39: Tensile Sample Test after Run

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Figure 3.40: Section Data input Figure 3.40: Section Data input

By plotting the node sequence in coordinate system, the data can be obtained in the By plotting the node sequence in coordinate system, the data can be obtained in the

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This is based on

This is based on the weight balance configuratiothe weight balance configuration for tn for the airframe fuselage. Thehe airframe fuselage. The following is the force applied on the

following is the force applied on the nodes of the FEA nodes of the FEA airframe fuselage as shown inairframe fuselage as shown in Table 3.2.

Table 3.2.

Table 3.2: Load Distribution Table 3.2: Load Distribution Node

Node 1g 1g Force(N) Force(N) 2.5g 2.5g Force(N) Force(N) 3.8g 3.8g Force(N) Force(N) Part/ComponenPart/Componentt 1

1 -49.05 -49.05 -122.625 -122.625 -186.39 -186.39 Fuel Fuel TankTank 43, 44, 43, 44, 45, 46 45, 46 -206.53 -206.53 -516.32 -516.32 -784.8 -784.8 PilotPilot 53 53 -196.2 -196.2 -490.5 -490.5 -745.56 -745.56 PowerplaPowerplantnt

Table 3.3: Fixed Support Table 3.3: Fixed Support Fuselage Boundary Condition: Fuselage Boundary Condition:

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Figure 3.42: ANSys Load Definition Figure 3.42: ANSys Load Definition Pilot Pilot distributed distributed Load Load Engine/ Engine/ Powerplant Powerplant Load Load Fuel Tank Fuel Tank Load Load

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Figure 3.43: Hanging on cranes Figure 3.43: Hanging on cranes

The Figure 3.43 shows the airframe of the trike being held at the position of the fixed The Figure 3.43 shows the airframe of the trike being held at the position of the fixed

96.3cm 96.3cm

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3.10

3.10 Assembly Assembly of of AirframeAirframe

The airframe was assembled together. The fuselage was completed with the wings and The airframe was assembled together. The fuselage was completed with the wings and joined as sho

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RESULTS AND DISCUSSIONS RESULTS AND DISCUSSIONS

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Table 4.2: Chemical Properties of

Table 4.2: Chemical Properties of Aluminium Alloy 6063 (%)Aluminium Alloy 6063 (%)

The minimum mechanical properties of the aluminium alloy 6063 can be produced as The minimum mechanical properties of the aluminium alloy 6063 can be produced as such:

such:

Table 4.3: 6063

Table 4.3: 6063 Aluminium Alloy Mechanical PropertiesAluminium Alloy Mechanical Properties Ultimate Tensile Strength

Ultimate Tensile Strength 89.6 MPa89.6 MPa

Tensile Yield Strength

Tensile Yield Strength 48.3 MPa48.3 MPa

Al = Al = remainder remainder Si = Si = 0.2~0.4 0.2~0.4 Fe = Fe = <0.35 <0.35 Cu = Cu = <0.1 <0.1 Mn = Mn = <0.1 <0.1 Mg = Mg = 0.45~0.9 0.45~0.9 Cr = Cr = <0.1 <0.1 Ti = Ti = <0.1 <0.1 Zn = Zn = <0.1 <0.1 Other elements = <0.05 Other elements = <0.05

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(4.2.1) (4.2.1)

The formula can be done: The formula can be done:

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The same result can be

The same result can be said for different thickness and diameter of said for different thickness and diameter of hollow beam. Thishollow beam. This concludes that the test occur some error due to standard or the material itself is not in concludes that the test occur some error due to standard or the material itself is not in standard. The test further continues using standardize tensile test of

standard. The test further continues using standardize tensile test of the material.the material.

4.3

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The results are as shown in Table 4.4. Using the tensile test machine, the result The results are as shown in Table 4.4. Using the tensile test machine, the result clearly shows that even using standards, the results are

clearly shows that even using standards, the results are slightly similar to the bendingslightly similar to the bending test. But the result can be corrected as t

test. But the result can be corrected as t o follow the standard by changing the crosso follow the standard by changing the cross section area which is inputted into the machine in square surface instead of arc section area which is inputted into the machine in square surface instead of arc surface.

surface.

The following is the table of the specification of sample inputted into the machine. The following is the table of the specification of sample inputted into the machine.

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Figure 4.1: Stress vs. Strain Graph of 26mm tube Figure 4.1: Stress vs. Strain Graph of 26mm tube

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Table 4.6: Result of Material Strength from Figure 4.2 Table 4.6: Result of Material Strength from Figure 4.2

Yield Strength, σ Yield Strength, σyieldyield

Specimen

Specimen 1 1 80 80 MPaMPa Specimen

Specimen 2 2 80 80 MPaMPa Average

Average 80 MPa80 MPa Modulus of Elasticity, E Modulus of Elasticity, E E1 E1 40 GPa40 GPa E2 E2 40 GPa40 GPa Average

Average 40 GPa40 GPa

Stress Vs Strain 33mm

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Table 4.7: Result of Material Strength from Figure 4.3 Table 4.7: Result of Material Strength from Figure 4.3

Yield Strength, σ Yield Strength, σyieldyield

Specimen

Specimen 1 1 120 120 MPaMPa Specimen

Specimen 2 2 120 120 MPaMPa Average

Average 120 MPa120 MPa Modulus of Elasticity, E Modulus of Elasticity, E E1 E1 30 GPa30 GPa E2 E2 30 GPa30 GPa Average

Average 30 GPa30 GPa

The result is used in ANSys by inputting into the material model library as shown: The result is used in ANSys by inputting into the material model library as shown:

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The following is the result of the ANSys application for 3.8g; The following is the result of the ANSys application for 3.8g;

Figure 4.4: Deformation of Airframe at 3.8g Figure 4.4: Deformation of Airframe at 3.8g

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For 2.5g; For 2.5g;

Figure 4.6: Deformation of Airframe at 2.5g Figure 4.6: Deformation of Airframe at 2.5g

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For 1g; For 1g;

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The results for

The results for the experiment can be concluded based on the tensile tthe experiment can be concluded based on the tensile t est doneest done on the material used and the analysis done for the fuselage airframe. The results can on the material used and the analysis done for the fuselage airframe. The results can be formed from the largest stress on the beam analyze against the yield strength of the be formed from the largest stress on the beam analyze against the yield strength of the material. The largest stress can be resolved from the ANSys of the airframe where the material. The largest stress can be resolved from the ANSys of the airframe where the 4 nodes of node 43, 44, 45, 46 are applied to the pilot weight average on 1g, 2.5g and 4 nodes of node 43, 44, 45, 46 are applied to the pilot weight average on 1g, 2.5g and 3.8g. This is done to compare maximum load factor, n of the airframe.

3.8g. This is done to compare maximum load factor, n of the airframe. Table 4.9:

Table 4.9: Maximum Stress ComparisonMaximum Stress Comparison Load

Load Factor, Factor, n n Deflection (mm) Deflection (mm) Maximum Maximum Stress Stress (at (at same same node node 45,46)45,46) 1g 1g 0.95 0.95 18.07MPa18.07MPa 2.5g 2.5g 14.55 14.55 36.33MPa36.33MPa 3.8g 3.8g 36.49 36.49 57.48MPa57.48MPa

The largest stress value is; The largest stress value is;

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load factor shows that t

load factor shows that the load can be increased up he load can be increased up to 1.39g.The following is the resultto 1.39g.The following is the result of load factor calculation:

of load factor calculation:

Table 4.10: Load

Table 4.10: Load Factor ComparisonFactor Comparison Load

Load Factor, Factor, n n Safety Safety FactorFactor

1g 4.43 1g 4.43 2.5g 2.20 2.5g 2.20 3.8g 1.39 3.8g 1.39

Therefore, the results show a maximum load factor

Therefore, the results show a maximum load factor of 4.43 for 1g of 4.43 for 1g load distributionload distribution. The. The airframe is still safe at

airframe is still safe at restricted maneuverirestricted maneuvering when submitted to 2.5g ng when submitted to 2.5g as the loadas the load factor is 2.2 the airframe is not

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CONCLUSION AND RECOMMENDATIONS CONCLUSION AND RECOMMENDATIONS

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5.2 Recommendation

Some recommendations can be realized in improving the design of the ultralight Some recommendations can be realized in improving the design of the ultralight airframe fuselage:

airframe fuselage:



 Materials Materials needed needed to be to be aircraft aircraft grade ograde or similr similar to ar to the standathe standard ord of thef the

airframe design to accomplish structural safety airframe design to accomplish structural safety



 The wThe weight oeight of the f the airframe airframe should should be lbe lighter. ighter. Additional Additional design design promptprompt

suggest reduction of modification of the airframe design by using stronger suggest reduction of modification of the airframe design by using stronger material grade

material grade



 The centeThe center of r of gravity gravity of the of the airframe airframe is nois not feasiblet feasible. The . The design design based based onon

single seated fuselage. The dimension differs from the adopted design of single seated fuselage. The dimension differs from the adopted design of two seated fuselage.

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REFERENCES REFERENCES

[1]

[1] A.C. A.C. Kermode Kermode (2006), (2006), D.R.PhilpoD.R.Philpott, tt, R.H.BernardR.H.Bernard, , Mechanics Mechanics of of Flight, Flight, 11th11th Edition, University of Hertfordshire, Prentice Hall

Edition, University of Hertfordshire, Prentice Hall [2]

(81)

[10]

[10] Wahyu Wahyu Kuntjoro Kuntjoro (2005), (2005), An An Introduction Introduction to to the the Finite Finite Element Element Method, Method, McGraw- McGraw-Hill Education

Hill Education [11]

[11] Airframe Airframe Failure Failure AccidentsAccidents www.eaa.org/(

www.eaa.org/(http://www.eaa.ohttp://www.eaa.org/lightplanerg/lightplaneworld/articlesworld/articles/1009_trike_/1009_trike_fatality.asfatality.as p) (Accessed 15 July 2013)

p) (Accessed 15 July 2013) [12]

[12] Ultralight Ultralight RegulationRegulationss

www.faa.gov/ (Accessed 15 July

www.faa.gov/ (Accessed 15 July 2013)2013) [13]

[13] Ultralight Ultralight RegulationsRegulations

www.usua.org/Rules/faa103.htm

www.usua.org/Rules/faa103.htm (Accessed 15 July 2013)(Accessed 15 July 2013) [14]

[14] Ultralight Ultralight NewsNews www.flyingstar

www.flyingstart.org (Accessed t.org (Accessed 15 July 15 July 2013)2013) [15]

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APPENDICES APPENDICES

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APPENDIX A APPENDIX A NODES NODES Nodes Nodes No. No. X-Coordinate

X-Coordinate Y-Coordinate Y-Coordinate Z-CoordinateZ-Coordinate

1 1 0.0000000000.000000000000 000 0.000000000000 0.000000000000 40.0000000000040.00000000000 2 2 3 3 0.0000000000.000000000000 000 0.000000000000 0.000000000000 -720.0000000-720.0000000000000 4 4 0.0000000000.000000000000 000 0.000000000000 0.000000000000 -1495.000000-1495.000000000000 5 5 -200.000000-200.0000000000 0000 -320.00000-320.0000000000 00000 -720.0000000-720.0000000000000 6 6 -378.333333-378.3333333333 3333 -685.00000-685.0000000000 00000 -720.0000000-720.0000000000000

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19 19 181.2500000000 181.2500000000 -1415.500-1415.500000000 000000 890.4000000000890.4000000000 20 20 75.00000000000 75.00000000000 -1415.000-1415.000000000 000000 1194.0000000001194.000000000 21 21 0.000000000000 0.000000000000 -1415.000-1415.000000000 000000 1194.0000000001194.000000000 22 22 -75.0000000-75.00000000000 0000 -1415.0000000-1415.000000000 00 1194.0000001194.000000000000 23 23 -181.0000000-181.0000000000 000 -1415.5000000-1415.500000000 00 890.0000000890.0000000000000 24 24 -287.0000000-287.0000000000 000 -1415.0000000-1415.000000000 00 586.0000000586.0000000000000 25 25 -393.5000000-393.5000000000 000 -1415.0000000-1415.000000000 00 282.8000000282.8000000000000 26 26 -500.0000000-500.0000000000 000 -1415.0000000-1415.000000000 00 -20.400000000-20.4000000000000 27 27 -617.5000000-617.5000000000 000 -1415.0000000-1415.000000000 00 -370.20000000-370.200000000000 28 28 -551.2500000-551.2500000000 000 -1415.0000000-1415.000000000 00 -720.00000000-720.000000000000 29 29 -367.5000000-367.5000000000 000 -1415.0000000-1415.000000000 00 -720.00000000-720.000000000000

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42 42 96.00000000000 96.00000000000 -1415.000-1415.000000000 000000 586.5333333333586.5333333333 43 43 -200.0000000-200.0000000000 000 -1315.0000000-1315.000000000 00 -140.40000000-140.400000000000 44 44 200.0000000000 200.0000000000 -1315.000-1315.000000000 000000 -140.4000000-140.4000000000000 45 45 200.0000000000 200.0000000000 -1315.000-1315.000000000 000000 -540.4000000-540.4000000000000 46 46 -200.0000000-200.0000000000 000 -1315.0000000-1315.000000000 00 -540.40000000-540.400000000000 47 47 0.000000000000 0.000000000000 -1315.000-1315.000000000 000000 -540.4000000-540.4000000000000 48 48 200.0000000000 200.0000000000 -965.00000-965.0000000000 00000 -540.4000000-540.4000000000000 49 49 -200.0000000-200.0000000000 000 -965.000000000-965.0000000000 0 -540.40000000-540.400000000000 50 50 0.000000000000 0.000000000000 -1670.000-1670.000000000 000000 1194.0000000001194.000000000 51 51 -500.0000000-500.0000000000 000 -1315.0000000-1315.000000000 00 -141.40000000-141.400000000000 52 52 500.0000000000 500.0000000000 -1315.000-1315.000000000 000000 -141.4000000-141.4000000000000

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72 72 -3203.80000-3203.800000000 0000 224.0000000000224.0000000000 73 73 -3948.60000-3948.600000000 0000 276.1000000000276.1000000000 74 74 -4613.70000-4613.700000000 0000 322.6000000000322.6000000000 75 75 -4693.50000-4693.500000000 0000 328.2000000000328.2000000000 76 76 -124.7000000-124.7000000000 000 8.700000000000 8.700000000000 -1476.00000-1476.0000000000000 77 77 -224.5000000-224.5000000000 000 15.70000000000 15.70000000000 -1476.00000-1476.0000000000000 78 78 -956.3000000-956.3000000000 000 66.90000000000 66.90000000000 -1476.00000-1476.0000000000000 79 79 -1351.70000-1351.700000000 0000 94.50000000000 94.50000000000 -1476.00000-1476.0000000000000 80 80 -1608.10000-1608.100000000 0000 112.4000000000 112.4000000000 -1476.00000-1476.0000000000000 81 81 -1701.10000-1701.100000000 0000 119.0000000000 119.0000000000 -1476.00000-1476.0000000000000 82 82 -2458.90000-2458.900000000 0000 171.9000000000 171.9000000000 -1476.00000-1476.0000000000000

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95 95 -1434.50000-1434.500000000 0000 100.3000000000 100.3000000000 -1816.00000-1816.0000000000000 96 96 -2087.70000-2087.700000000 0000 146.0000000000 146.0000000000 -1816.00000-1816.0000000000000 97 97 -2740.90000-2740.900000000 0000 191.7000000000 191.7000000000 -1816.00000-1816.0000000000000 98 98 -3394.10000-3394.100000000 0000 237.3000000000 237.3000000000 -1816.00000-1816.0000000000000 99 99 -4047.30000-4047.300000000 0000 283.0000000000 283.0000000000 -1816.00000-1816.0000000000000 100 100 -4693.5000-4693.500000000 00000 328.2000000000 328.2000000000 -1816.0000-1816.00000000000000 101 101 -1434.5000-1434.500000000 00000 100.3000000000 100.3000000000 -1476.0000-1476.00000000000000 102 102 -212.30000-212.3000000000 00000 189.3000000000 189.3000000000 -100.00000-100.000000000000000 103 103 -209.30000-209.3000000000 00000 232.2000000000 232.2000000000 -180.00000-180.000000000000000 104 104 -207.20000-207.2000000000 00000 262.1000000000 262.1000000000 -380.00000-380.000000000000000 105 105 -944.90000-944.9000000000 00000 240.5000000000 240.5000000000 -100.00000-100.000000000000000

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118 118 -3933.4000-3933.400000000 00000 492.6000000000 492.6000000000 -180.00000-180.000000000000000 119 119 -3931.0000-3931.000000000 00000 522.5000000000 522.5000000000 -380.00000-380.000000000000000 120 120 -4681.3000-4681.300000000 00000 501.8000000000 501.8000000000 -100.00000-100.000000000000000 121 121 -4677.8000-4677.800000000 00000 544.6000000000 544.6000000000 -180.00000-180.000000000000000 122 122 -4676.5000-4676.500000000 00000 574.6000000000 574.6000000000 -380.00000-380.000000000000000 123 123 124.700000000124.7000000000 0 8.7000000000008.700000000000 124 124 224.500000000224.5000000000 0 15.7000000000015.70000000000 125 125 956.300000000956.3000000000 0 66.9000000000066.90000000000 126 126 1351.700000001351.700000000 0 94.5000000000094.50000000000 127 127 1608.100000001608.100000000 0 112.4000000000112.4000000000 128 128 1701.100000001701.100000000 0 119.0000000000119.0000000000

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141 141 1701.100000001701.100000000 0 119.0000000000 119.0000000000 -1476.000000-1476.000000000000 142 142 2458.900000002458.900000000 0 171.9000000000 171.9000000000 -1476.00000-1476.0000000000000 143 143 2917.900000002917.900000000 0 204.0000000000 204.0000000000 -1476.00000-1476.0000000000000 144 144 3117.400000003117.400000000 0 218.0000000000 218.0000000000 -1476.00000-1476.0000000000000 145 145 3203.800000003203.800000000 0 224.0000000000 224.0000000000 -1476.00000-1476.0000000000000 146 146 3948.600000003948.600000000 0 276.1000000000 276.1000000000 -1476.00000-1476.0000000000000 147 147 4613.700000004613.700000000 0 322.6000000000 322.6000000000 -1476.00000-1476.0000000000000 148 148 4693.500000004693.500000000 0 328.2000000000 328.2000000000 -1476.00000-1476.0000000000000 149 149 124.700000000124.7000000000 0 8.700000000000 8.700000000000 -737.900000-737.90000000000000 150 150 872.700000000872.7000000000 0 61.02000000000 61.02000000000 -737.900000-737.90000000000000 151 151 1608.100000001608.100000000 0 112.4000000000 112.4000000000 -737.900000-737.90000000000000

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164 164 207.200000000207.2000000000 0 262.1000000000 262.1000000000 -380.000000-380.00000000000000 165 165 944.900000000944.9000000000 0 240.5000000000 240.5000000000 -100.000000-100.00000000000000 166 166 941.500000000941.5000000000 0 283.4000000000 283.4000000000 -180.000000-180.00000000000000 167 167 939.000000000939.0000000000 0 313.3000000000 313.3000000000 -380.000000-380.00000000000000 168 168 1689.000000001689.000000000 0 292.5000000000 292.5000000000 -100.000000-100.00000000000000 169 169 1686.000000001686.000000000 0 335.4000000000 335.4000000000 -180.000000-180.00000000000000 170 170 1683.800000001683.800000000 0 365.3000000000 365.3000000000 -380.000000-380.00000000000000 171 171 2447.300000002447.300000000 0 345.6000000000 345.6000000000 -100.000000-100.00000000000000 172 172 2443.800000002443.800000000 0 388.4000000000 388.4000000000 -180.000000-180.00000000000000 173 173 2441.800000002441.800000000 0 418.4000000000 418.4000000000 -380.000000-380.00000000000000 174 174 3190.800000003190.800000000 0 397.5000000000 397.5000000000 -100.0000000-100.0000000000000

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187 187 0.000000000000.000000000000 0 951.5000000000 951.5000000000 -3871.20000-3871.2000000000000 188 188 0.000000000000.000000000000 0 171.5000000000 171.5000000000 -3943.00000-3943.0000000000000 189 189 0.000000000000.000000000000 0 -306.40000000-306.4000000000 00 -3872.9000000-3872.90000000000 190 190 0.000000000000.000000000000 0 171.5000000000 171.5000000000 -3485.00000-3485.0000000000000 191 191 100.000000000100.0000000000 0 94.50000000000 94.50000000000 -3485.00000-3485.0000000000000 192 192 376.100000000376.1000000000 0 94.50000000000 94.50000000000 -4075.00000-4075.0000000000000 193 193 1357.000000001357.000000000 0 94.50000000000 94.50000000000 -4075.00000-4075.0000000000000 194 194 1357.000000001357.000000000 0 94.50000000000 94.50000000000 -3485.00000-3485.0000000000000 195 195 1357.000000001357.000000000 0 94.50000000000 94.50000000000 -3207.80000-3207.8000000000000 196 196 750.000000000750.0000000000 0 94.50000000000 94.50000000000 -2785.00000-2785.0000000000000 197 197 500.000000000500.0000000000 0 94.50000000000 94.50000000000 -2785.00000-2785.0000000000000

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210 210 4047.300000004047.300000000 0 283.0000000000 283.0000000000 -1476.00000-1476.0000000000000 211 211 -2087.7000-2087.700000000 00000 146.0000000000 146.0000000000 -1476.0000-1476.00000000000000 212 212 -2740.9000-2740.900000000 00000 191.7000000000 191.7000000000 -1476.0000-1476.00000000000000 213 213 -3394.1000-3394.100000000 00000 237.3000000000 237.3000000000 -1476.0000-1476.00000000000000 214 214 -4047.3000-4047.300000000 00000 283.0000000000 283.0000000000 -1476.0000-1476.00000000000000 215 215 -471.09400-471.0940000000 00000 94.50000000000 94.50000000000 -2785.0000-2785.00000000000000 216 216 471.094000000471.0940000000 0 94.50000000000 94.50000000000 -2785.00000-2785.0000000000000 217 217 -1608.8741-1608.874111442 11442 -618.3707865-618.3707865169 169 -76.5524879-76.552487961486148 218 218 -1608.8741-1608.874111442 11442 -618.3707865-618.3707865169 169 -753.461453-753.46145379507950 219 219 1700.366888321700.366888328 8 -611.95024077-611.9502407705 05 -76.552487961-76.5524879614848 220 220 1700.366888321700.366888328 8 -611.95024077-611.9502407705 05 -753.4614537-753.4614537950950

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APPENDIX B APPENDIX B DETAIL DETAIL DESIGNS DESIGNS

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Table 6.1: Bill of

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Figure 6.3: Trike

Figure 6.3: Trike Nose DesignNose Design Nose Wheel Support

Nose Wheel Support Paddle Paddle

Rod End Bearing M8 Rod End Bearing M8

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81 81

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APPENDIX C APPENDIX C

Fuselage Cost Analysis Fuselage Cost Analysis Item

Item no. no. Part Part name name Specifications Specifications Cost / Cost / Unit Unit Unit Unit Overall Overall Cost Cost (RM)(RM) 1

1 Hollow BeamHollow Beam 26mm 26mm Outer diameter = 26mm Outer diameter = 26mm Thickness = 1.37mm Thickness = 1.37mm Aluminium 6063 Aluminium 6063 RM RM 5.50/1m 5.50/1m 10.84m 10.84m 60.5060.50 2

2 Hollow BeamHollow Beam 33mm 33mm Outer diameter = 33mm Outer diameter = 33mm Thickness = 1.33mm Thickness = 1.33mm Aluminium 6063 Aluminium 6063 RM RM 6.80/1m 6.80/1m 38.32m 38.32m 260.60260.60 3

3 Square HollowSquare Hollow Beam 55mm Beam 55mm Length = 55mm Length = 55mm Width = 55mm Width = 55mm Thickness = 1.5mm Thickness = 1.5mm Mild Steel Mild Steel RM RM 40.00/1m 40.00/1m 1.5m 1.5m 60.0060.00 5

5 Plate Plate Thickness Thickness = = 2mm 2mm RM RM 200.00/1m^2 200.00/1m^2 0.6m^2 0.6m^2 120.00120.00 6 Wheels 6 Wheels Diameter = 256mm Diameter = 256mm Width = 82mm Width = 82mm Max load capacity = 68kg Max load capacity = 68kg

RM

RM 20.00/unit 20.00/unit 3 3 60.0060.00 7

7 Seat Seat Seat Seat Area Area = = 50mm^2 50mm^2 RM RM 30.00/unit 30.00/unit 1 1 30.0030.00 8

8 Burger Burger BearingBearing Outer Diameter = 40mmOuter Diameter = 40mm Inner Diameter = 35mm

Inner Diameter = 35mm RM RM 15.00/unit 15.00/unit 2 2 30.0030.00 9

9 Rod Rod End End Bearing Bearing Inner Inner Diameter Diameter = = 8mm 8mm RM RM 18.00/unit 18.00/unit 4 4 72.0072.00

10 10 M8 M8 BoltBolt Length = 55mm Length = 55mm Diameter = 8mm Diameter = 8mm 2 Washers and Nut 2 Washers and Nut

RM

RM 0.30/unit 0.30/unit 202 202 60.6060.60 Overall