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Front Wing design and build1

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GrantL
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Front Wing design and build1

Postby GrantL » Sat Jul 15, 2017 12:44 am

I have been riding my first Foil home build for 5 months now and really enjoying it.
20170711_160227.jpg
Finished Front Wing Build1
I started a new project (front wing) see above, mucking around with a modeling package. I wanted to compare how different profiles worked , trying to understand what worked better and what didn't. I want to share my first design , likely to be fast on the water but not necessarily super friendly to ride. Build2 FUTURE design yet to start will be a lower AR easier to ride.

Here are images of the generated graphs of the profile I used (RG08) for DESIGN1 . The second image plots results for a batch analysis across a range of Reynold''s numbers 30,000 to 3.5million.
rg08 profile graph.png
RG08 Profile
RG08 renyolds 0.3 - 3.5milllion batch analysis.png
Batch Analysis
The profile is applied onto a 3d wing on a model. The model includes the mast , fuselage , stab ,board and rider.
RG08 model plan.png
Front Wing Pan
RG08 model1.png
Front Wing Model
And the picture story to follow

Antoine
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Re: Front Wing design and build1

Postby Antoine » Sat Jul 15, 2017 3:14 am

Nice work.

GrantL
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Re: Front Wing design and build1

Postby GrantL » Sat Jul 15, 2017 10:44 pm

image.png
2 halves , twill laid in mold
image2.png
double bias cut to lay up
image3.png
unidirectional lay up

GrantL
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Re: Front Wing design and build1

Postby GrantL » Sun Jul 16, 2017 12:01 am

image4.png
underneath wing , reduced layup. NO room
image5.png
Vacuum infusion 2 halves complete
image6.png
machined to part line , stripped from mold
I don't have any pics of the laminating together, but originally I was going to vacuum bag inside and outside to fuse 2 halves. But with such a small cavity I decided against that method. What I did instead was laminate a internal fillet out of thin S glass using the inside of the carbon halves as molds. I allowed for the thickness of 400gsm double bias carbon , which would eventually laminate the 2 front leading edges together. I vacuumed the S glass onto the carbon halves to get the exact profile. Finally I wet laminated the double bias carbon fiber supported by the S glass "fillet backing".Then I laid 1 layer of 150gsm of twill over the complete wing part line. This fused the trailing edge which ends up to be around 20mm wide , and the front edge which is around 2.5mm wide. The double bias lapped the front 30mm both top and bottom.
This was all assembled back into my mold and vacuumed over night to cure. When I popped part from mold I has the twill (0.15mm) extending out all around the part.
I then carefully trimmed back and sanded smooth on part line.
image7.png
perfect fit on part line , ready to laminate together
image8.png
underside
image9.png
finished , view of leading edge
image10.png
view of trailing edge, 0.8mm square. not too sharp
image11.png
underside view of reflex profile

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mopman365
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Re: Front Wing design and build1

Postby mopman365 » Mon Jul 17, 2017 7:36 am

Thanks GrantL, appreciate the detailed info. One thing I'm not getting - do you en up with a hollow wing or do you fill the cavity up with glass? Sorry, can't figure that out from your description.

GrantL
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Re: Front Wing design and build1

Postby GrantL » Mon Jul 17, 2017 7:59 am

No hollow. The overall carbon thickness per halves is 2.5mm.
Max wing height is around 11mm. So cavity is around 6mm tapering to 0 at wing tips. The laps I detailed fuse the leading edge. Wing is extremely stiff in bending and torsional stiffness.

GrantL
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Re: Front Wing design and build1

Postby GrantL » Mon Jul 17, 2017 8:44 am

This might explain better
Attachments
lap_detail.png
Lap detail to connect 2 halves
lap_detail.png (5.61 KiB) Viewed 847 times

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mopman365
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Re: Front Wing design and build1

Postby mopman365 » Tue Jul 18, 2017 6:17 am

Very nice indeed. Guessing there's a bit of sanding required on the inside mating surfaces, especially the insides of the trailing edge, before joining the two halves?

GrantL
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Re: Front Wing design and build1

Postby GrantL » Tue Jul 18, 2017 6:42 am

mopman365 wrote:
Tue Jul 18, 2017 6:17 am
Very nice indeed. Guessing there's a bit of sanding required on the inside mating surfaces, especially the insides of the trailing edge, before joining the two halves?
No I don't sand at all. Carbon dust is not good. What I do instead is scrap the carbon carefully back to part line with a tungsten carbide 50mm wide scraper . Scraping is easier to control. It took about 1hour per halve to get a perfect joint

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mopman365
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Re: Front Wing design and build1

Postby mopman365 » Tue Jul 18, 2017 9:11 am

GrantL wrote:
Tue Jul 18, 2017 6:42 am
mopman365 wrote:
Tue Jul 18, 2017 6:17 am
Very nice indeed. Guessing there's a bit of sanding required on the inside mating surfaces, especially the insides of the trailing edge, before joining the two halves?
No I don't sand at all. Carbon dust is not good. What I do instead is scrap the carbon carefully back to part line with a tungsten carbide 50mm wide scraper . Scraping is easier to control. It took about 1hour per halve to get a perfect joint
Hmmm, so like a surform scraper or a blade-type tool?


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