High aspect ratio aircraft have a significantly reduced induced drag, but have only limited installation space for control surfaces near the wingtip. This paper describes a multidisciplinary design methodology for a morphing aileron that is based on pressure-actuated cellular structures (PACS). The focus of this work is on the transient dynamic system behavior of the multi-functional aileron. Decisive design aspects are the actuation speed, the resistance against external loads, and constraints preparing for a future wind tunnel test. The structural stiffness under varying aerodynamic loads is examined while using a reduced-order truss model and a high-fidelity finite element analysis. The simulations of the internal flow investigate the transient pressurization process that limits the dynamic actuator response. The authors present a reduced-order model based on the Pseudo Bond Graph methodology enabling time-efficient flow simulation and compare the results to computational fluid dynamic simulations. The findings of this work demonstrate high structural resistance against external forces and the feasibility of high actuation speeds over the entire operating envelope. Future research will incorporate the fluid–structure interaction and the assessment of load alleviation capability.

Background: The design of compliant mechanisms requires detailed knowledge about the stiffness properties of their flexible segments. However, there are no standardized test methods for flexure hinges, and therefore the influence of manufacturing-specific effects, such as anisotropy, on the stiffness properties cannot be quantified. Objective: This paper presents novel test methods for variable cross-section flexure hinges subjected to large deformations and pure bending loading, which determine the bending stiffness of flexure hinges over their entire deflection range using a universal testing machine. Methods: The novel test methods for flexure hinges are based on the tensile test, the four-point bending test (FPBT), and the column bending test (CBT). These test methods were initially formulated for constant cross-section specimens, but are adapted in this study to examine variable cross-section specimens. The derived test methods are validated by using isotropic materials with well-known properties and by comparing the calculated deflections with deflections measured by means of image processing. Results: The deflection validation shows that the adapted CBT (aCBT) is accurate over the entire deflection range, achieving curvature of up to $$\kappa =0.40\;\text {mm}^{-1}$$κ = 0.40 mm - 1 , whereas the maximum curvature in the adapted FPBT (aFPBT) is limited by the test methodology to about $$\kappa =0.15\;\text {mm}^{-1}$$κ = 0.15 mm - 1 . At small strains, the flexural modulus determined in the aCBT and aFPBT agrees well with the Young’s modulus determined in the tensile test, as would be expected for isotropic materials. Conclusion: The aCBT proves to be a suitable test method for flexure hinges at large deflections, whereas the stiffness characterization at small deflections can be performed with both the aCBT and the aFPBT. The presented test methods validated on isotropic materials form the basis for characterizing anisotropic flexure hinges with geometry-dependent stiffness properties.

Shape-variable structures can change their geometry in a targeted way and thus adapt their outer shape to different operating conditions. The potential applications in aviation are manifold and far-reaching. The substitution of conventional flaps in high-lift systems or even the deformation of entire wing profiles is conceivable. All morphing approaches have to deal with the same challenge: A conflict between minimizing actuating forces on the one hand, and maximizing structural deflections and resistance to external forces on the other. A promising concept of shape variability to face this challenging conflict is found in biology. Pressure-actuated cellular structures (PACS) are based on the movement of nastic plants. Firstly, a brief review of the holistic design approach of PACS is presented. The aim of the following study is to investigate manufacturing possibilities for woven flexure hinges in closed cellular structures. Weaving trials are first performed on the material level and finally on a five-cell PACS cantilever. The overall feasibility of woven fiber reinforced plastics (FRP)-PACS is proven. However, the results show that the materials selection in the weaving process substantially influences the mechanical behavior of flexure hinges. Thus, the optimization of manufacturing parameters is a key factor for the realization of woven FRP-PACS.

The use of pressure-actuated cellular structures (PACS) is an effective approach for the application of compliant mechanisms. Analogous to the model in nature, the Venus flytrap, they are made of discrete pressure-activated rows and can be deformed with high stiffness at a high deformation rate. In previous work, a new innovative approach in their integral textile-based manufacturing has been demonstrated based on the weaving technique. In this work, the theoretical and experimental work on the further development of PACS from simple single-row to double-row PACS with antagonistic deformation capability is presented. Supported by experimental investigations, the necessary adaptations in the design of the textile preform and the polymer composite design are presented and concretized. Based on the results of pre-simulations of the deformation capacity of the new PACS, their performance was evaluated, the results of which are presented.