Design and Analysis of a Topology-Optimized Quadcopter Drone Frame

Abstract

This study focuses on the analysis and optimization of a drone frame design to enhance its performance characteristics. The design underwent drop testing, stress analysis, displacement analysis, and flow simulation to evaluate its structural integrity, deformation resistance, and aerodynamic performance. Furthermore, topology optimization techniques were employed to achieve a 30% weight reduction while maintaining the structural integrity of the drone frame. The results of the drop test analysis revealed that Design 2 exhibited lower stress levels compared to Design 1, indicating improved load distribution and structural integrity. However, Design 1 demonstrated lower displacement values, suggesting better resistance to deformation. The flow analysis indicated that Design 1 achieved lower flow velocities, indicating superior propulsion and aerodynamic performance. Through topology optimization, the mass of the drone frame was successfully reduced by 30% without compromising structural integrity. The optimized design exhibited improved stress management, reduced displacement, and slightly higher flow velocities compared to the initial design. These improvements contribute to enhanced agility, maneuverability, and energy efficiency of the drone. The findings of this study highlight the importance of considering stress distribution, displacement, and aerodynamic performance in drone design and optimization. The results provide valuable insights for the development of efficient and reliable drones.

Keywords

• Drone
• drop test
• topology optimization
• FEA analysis
• flow simulation

Kaynakça

1. [1] Sundararaj, S., Dharsan, K., Ganeshraman, J., & Rajarajeswari, D. Structural and modal analysis of hybrid low altitude self-sustainable surveillance drone technology frame. Materials Today: Proceedings, 37 (2021) 409-418.
2. [2] Mohsan S.A.H., Khan M.A., Noor F., Ullah I., & Alsharif M.H. Towards the unmanned aerial vehicles (UAVs): A comprehensive review. Drones, 6(6) (2022) 147-149.
3. [3] Agarwal H., Singhal A., & Raj K.H. 3D Printed Quadcopter. In Advances in Systems Engineering: Select Proceedings of NSC 2019. Singapore: Springer, (2021) 491-499,
4. [4] Zhu J.H., Zhang W.H., & Xia L. Topology optimization in aircraft and aerospace structures design. Archives of Computational Methods in Engineering, 23 (2016) 595-622.
5. [5] Bajirao M.S., Vijay K.P., Sudhir G.R., Pandurang Z.H., & Prasanna R. Design Optimization of Drone Frame. International Journal of Mechanics and Design, 8(1) (2022) 25-32.
6. [6] Satam S., Topology Optimization of UAV Drone frame. https://www.linkedin.com/pulse/topology-optimization-uav-drone-frame-sanay-satam/?trackingId=rwnSsEkvRq%2BvfnaCQMSFXw%3D%3D
7. [7] Nvss S., Esakki B., Yang L.J., Udayagiri C., & Vepa K.S. Design and development of unibody quadcopter structure using optimization and additive manufacturing techniques. Designs, 6(1) (2022) 8-12.
8. [8] Bright J., Suryaprakash R., Akash S., & Giridharan A. Optimization of quadcopter frame using generative design and comparison with DJI F450 drone frame. In IOP Conference Series: Materials Science and Engineering, 1012(1) (2021) 012019.

9. [9] Dev, P. K., Balaji, C., & Gurusideswar, S. Material characterization of sugarcane bagasse/epoxy composites for drone frame material. Materials Today: Proceedings, 68 (2022) 2586-2590.
10. [10] Anand, S., & Mishra, A. K. High-Performance Materials used for UAV Manufacturing: Classified Review. International Journal of All Research Education and Scientific Methods, 10(7) (2022) 2811-2819.
11. [11] Shelare, S., Belkhode, P., Nikam, K. C., Yelamasetti, B., & Gajbhiye, T. A payload based detail study on design and simulation of hexacopter drone. International Journal on Interactive Design and Manufacturing, 18 (2023) 1-18.
12. [12] Husaini, H., Putra, D. I. O., Syahriza, S., & Akhyar, A. Stress and strain analysis of UAV hexacopter frame using finite element method. In AIP Conference Proceedings, 2613 (2023), 1-8.
13. [13] Yap, Y. L., Toh, W., Giam, A., Yong, F. R., Chan, K. I., Tay, J. W. S., & Ng, T. Y. Topology optimization and 3D printing of micro-drone: Numerical design with experimental testing. International Journal of Mechanical Sciences, 237 (2023), 107771.
14. [14] Parsons, J. S., Goodson, R.E., & Goldschmied, F.R. Shaping of axisymmetric bodies for minimum drag in incompressible flow. Journal of Hydronautics, 8(3) (1974) 100-107.
15. [15] Bras M., Warwick S., & Suleman A. Aeroelastic evaluation of a flexible high aspect ratio wing UAV: Numerical simulation and experimental flight validation, Aerospace Science and Technology, 122 (2022) 107400.
16. [16] Quintana, A., Graves, G., Hassanalian, M., & Abdelkefi, A. Aerodynamic analysis and structural integrity for optimal performance of sweeping and spanning morphing unmanned air vehicles. Aerospace Science and Technology, 110 (2021) 106458.
17. [17] Bergonti, F., Nava, G., Wüest, V., Paolino, A., L'Erario, G., Pucci, D., & Floreano, D. Co-Design Optimisation of Morphing Topology and Control of Winged Drones. arXiv preprint, 2309 (2023) 1-7.
18. [18] Ajanic, E., Feroskhan, M., Mintchev, S., Noca, F., & Floreano, D. Bioinspired wing and tail morphing extends drone flight capabilities. Science Robotics, 5(47) (2020) 1-12.
19. [19] Zhu H., Nie H., Zhang L., Wei X., & Zhang M. Design and assessment of octocopter drones with improved aerodynamic efficiency and performance. Aerospace Science and Technology, 106 (2020) 106206.
20. [20] Papadopoulos, C., Mitridis, D., & Yakinthos, K. Conceptual design of a novel unmanned ground effect vehicle (ugev) and flow control integration study. Drones, 6(1) (2022) 25-31.