UAV Wing leading edge crashworthiness behaviour under bird strike events: The added value of CF/PA additive solutions versus traditional metallic wing structures

In recent years, an increasing interest in innovative solutions design of aircraft structural components has been raised through both research and industrial fields, aimed at optimising weight and enhancing the ability to withstand both static and dynamic loads. This study compares the structural response to a bird strike phenomenon of a vertical tail of a UAV in standard metallic configuration with the one obtained from an innovative solution, equal in volume but with an internally designed architecture for an additive approach and manufactured by employing a carbon fibre reinforced filament engineered for metal replacement applications (carbon fibre, CF/polyamide, PA). The additive solution proposes the use of a 10 % infill and a lattice structure that completely replaces the traditional aircraft structure concept. This approach leads to a significant weight reduction, approximately 45 % compared to the traditional metallic configuration. The investigation was conducted through explicit numerical simulations considering different impact angles. The numerical model of the bird strike has been assessed by numerical-experimental comparison, simulating the impact of a bird with a flat plate. For this study, the Coupled Eulerian-Lagrangian (CEL) approach has been adopted to perform the simulation. The results were compared in terms of stress distribution, failure analysis, displacements, and energy-time and force-time diagrams. The work demonstrated that using innovative manufacturing processes, such as additive manufacturing, can significantly improve the bird strike resistance of aerospace structures. This improvement is achieved though the production of lighter, structurally collaborative geometries, by reducing the load transferred to the rest of the UAV by about 47 % and decreasing the displacement on the impact area by 53 %.