Little America's Cup----New Wing Out!, part 2 of 2
From Steve on sa:
So here is the tale:
The new wing had a couple of things that seemed worth trying and required some new solutions.
First was the thought that we could save a significant amount of weight by letting the whole thing be more flexible.
This would mean that the wing below the hounds would sag to leeward like a DN iceboat rig. We don't want to be that radical, but inherently there is nothing wrong with letting the rig sag as long as all the elements sag at the same rate. Associated with that thought is the idea that if the spans are shorter, it is easier to assure that all the elements sag at the same rate and that the #3 flap leading edge spar is much less stiffness critical and can also become lighter. The main spar was was built with this in mind, the laminate was reduced and the diameter was reduced to what we projected to be a safe minimum. It turned out that we were wrong on our original calculations, and that the mast wasn't stable when we tested it to it's projected full compression. We had to add laminate, and this gave back half the weight we hoped to save. We scrambled to redesign the hounds and mast base to minimize the prebend they imparted into the tube. That took a while.
We also felt that it would be advantageous to twist the entire span of the wing instead of just the bottom 25 feet ( as per Cogito)
The cost of doing this comes with complication, in order to have an intermediate control arms you have to build ones hat is not glued securely to the main mast, but which rotates proportionately with the twist mechanism. Thus if the top of the wing is a 12 degrees and the bottom is at zero, the two intermediate arms have to be at 4 and 8 degrees respectively. I wanted this to be self tacking and not require an additional layer of wing controls. I spent a lot of time mucking around but devised a fairly simple series of wheels and cams that would achieve this end. Fabricated it and got it working well in the shop.
A third goal was to improve the quality of the flying surfaces. The shrink film is effective and very light, but as the video from above shows, it is very stretchy and here are losses associated with the distortion of the flying surfaces. I haven't found any literature on this. It is just an observation and something I thought worth doing. So I planned to skin the new wing with very light composite panels ( weighing in the neighborhood of 0.10 lbs/ft^2) and reduce the internal structure to a minimum. The aerodynamic loads are really very small, and the compression loads imparted by the shrink film are relatively large. We reasoned we could save weight and get superior aerodynamics.
Last weekend we weighed the wing, and were pleased with the 141 pound weight. We put it up, and the controls all worked as designed. This was looking like a home run. All it had to do was behave when it was fully loaded, and the only way to find that out was to go sailing.
At this point all the time we wasted in he last 2 years bit back hard. If there was any significant problem, we were ******. There wasn't time to fix it. So we went down the list as if we were going to sail out to the race course right from the shop. Our first impression upon hitting the water was "WHO-ho!) the wing felt very slippery and clean. The efforts to reduce drag were obviously good. and even with two of us sitting on the hull, we had nice speed.
Then we started to notice that the surfaces were distorting and buckling in interesting ways.
Our old friend stretch had come back to haunt us and as a result, parts were being loaded in ways that they shouldn't be loaded. The first and most obvious one to be damaged was the #3 flap at boom level. Because the camber and twist cables were stretched, this element was being asked to do more than its fair share holding the main sheet and the flap up. The core sheered and it started to look increasingly like a beer can. By the end of the sail, it was pretty clear that we would have substantially rebuild the bottom of our 3# element. It will be faster and better to build a replacement than to repair that one. We don't have time for that.
A second series of issues showed up around the span wise sag of the mast. In order to twist and sag, these skins are held in place by slots and pins. This allows them to duck and dodge as they get loaded in various ways. We needed more relief than we had installed. As a result the leading edges sustained some damage that, while not game ending, will take some time to repair properly, and time is something we don't have. It is going to take a bit more sailing and testing before we understand the best combination of solutions.
Finally we have under-specified the ribs in our #2 element, particularly down near the bottom (where they are longest.) These need to be reinforced with gussets and some bulkheads. Once again, a fairly trivial fix but not something you do right in the next 3 days on top of everything else.
The final bug bear is the stretch in the control system. We were conscious of this all along and sized our cordage for stretch more than strength. In retrospect, I should have gone old school and done it all with wire. But I get carried away by the miracle that is modern line and thought I could go straight to the end game. Bad judgement on my part. I know we can sort this out, but is is going to take some time and we will probably trash a few more surfaces as we do. Knowing that there is an end, and getting there is just a matter of time. We are out of time.
So the take away is that I believe we have a good idea. We tried about 3 things too many at the same time, and ran out of time to get them working well enough in concert to go racing. Unfortunately, they are all linked, and you don't get one without the others. The weight saving is contingent on the control system working, and the skins are critical to the weight savings. We feel that the wing has enough potential that we didn't want to start down the road of half *** ed jungle repairs. We feel that if we do that, we can likely throw away too much of the work done over the last 6 months and end up with a piece of junk. If on the other hand we proceed thoughtfully, we could have a superior wing and the basis of future development. So we have to endure short term disappointment in the hopes of long term advancement. This is the kind of decision we ought to make as adults. But GODDAMNIT.
SHC
Beatings will continue until morale improves.
Note the spanwise sag-like an iceboat- in the left picture: