Exploration of distributed propeller regional aircraft design

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Exploration of distributed propeller regional aircraft design Baizura Bohari 1,2, Emmanuel Benard 1, Murat Bronz 2 1 University of Toulouse - ISAE Supaero, Dept.

1 Exploration of distributed propeller regional aircraft design Baizura Bohari 1,2, Emmanuel Benard 1, Murat Bronz 2 1 University of Toulouse - ISAE Supaero, Dept. of Aeronautic and Space Vehicles Design (DCAS) 2 University of Toulouse - ENAC, UAV Laboratory F juillet 2018 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

2 Outline 1 Introduction The big picture 2 Multidisciplinary Design Analysis (MDA) General framework Fixed-wing Aircraft Sizing Tool - FAST 3 Aerodynamic Module Modeling Frameworks 4 Verification and Synthesis Results Validation - Aerodynamic model Propeller-Wing Interaction -Linear Propeller-Wing Interaction - Non-linear with high lift device Validation - FAST 5 Conclusions and Future Works Conclusions Future Works 6 References Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

3 Plan 1 Introduction 2 Multidisciplinary Design Analysis (MDA) 3 Aerodynamic Module 4 Verification and Synthesis Results 5 Conclusions and Future Works 6 References Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

4 Plan 1 Introduction The big picture Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

NASA Illustration, Scalable Convergent Electric Propulsion Technology Operations Research (SCEPTOR) project, https://www.nasa.

5 Distributed Propellers Aircraft Concept FIGURE 1 ESAero NASA X-57 Maxwell [2] 1 FIGURE 2 Vahana, the self-piloted, EVTOL Aircraft from A3 by Airbus NASA Illustration, Scalable Convergent Electric Propulsion Technology Operations Research (SCEPTOR) project, Feb Vahana, the self-piloted, EVTOL Aircraft from A3 by Airbus, Jun 2018 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

6 Distributed Propellers Aircraft Concept FIGURE 1 ESAero NASA X-57 Maxwell [2] 1 FIGURE 2 Vahana, the self-piloted, EVTOL Aircraft from A3 by Airbus. 2 Features : - Multiple propellers distributed along the wing span - OEI condition less stringent - Wing area reduced/shorter Takeoff Field Length - High C L,max 1. NASA Illustration, Scalable Convergent Electric Propulsion Technology Operations Research (SCEPTOR) project, Feb Vahana, the self-piloted, EVTOL Aircraft from A3 by Airbus, Jun 2018 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

7 Distributed Propellers Aircraft Concept FIGURE 1 ESAero NASA X-57 Maxwell [2] 1 Features : - Multiple propellers distributed along the wing span - OEI condition less stringent - Wing area reduced/shorter Takeoff Field Length FIGURE 2 Vahana, the self-piloted, EVTOL Aircraft from A3 by Airbus. 2 Issues : Unconventional configuration - No semi-empirical formula - Need cheap prediction tools ) low fidelity - High C L,max 1. NASA Illustration, Scalable Convergent Electric Propulsion Technology Operations Research (SCEPTOR) project, Feb Vahana, the self-piloted, EVTOL Aircraft from A3 by Airbus, Jun 2018 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

8 Transformation Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

9 Transformation Objectives : Determine the viability of a concept and optimize it in a limited domain Monitor a large number of parameters and interaction between disciplines Estimate the aircraft performance for a given mission Reduce the number of late modifications Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

number of late modifications Expected outcomes : New weight distribution Propellers-wing interaction, Propellers-control

10 Transformation Objectives : Determine the viability of a concept and optimize it in a limited domain Monitor a large number of parameters and interaction between disciplines Estimate the aircraft performance for a given mission Reduce the number of late modifications Expected outcomes : New weight distribution Propellers-wing interaction, Propellers-control surfaces interaction Specific modules integration Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

11 Plan 1 Introduction 2 Multidisciplinary Design Analysis (MDA) 3 Aerodynamic Module 4 Verification and Synthesis Results 5 Conclusions and Future Works 6 References Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

12 Plan 2 Multidisciplinary Design Analysis (MDA) General framework Fixed-wing Aircraft Sizing Tool - FAST Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

13 Framework General multidisciplinary analysis framework[3] 3 Aircraft Design Variables Mission requirements 0, 5!1: MDO: Optimization 1: Fuel weight t SFC t 2: Total weight t Load t 3: Lift t Drag t Optimized propulsion coe cients 5: SFC 1: Propulsion system sizing and integration 2: Propulsion mass/weight 3: Propulsion power and thrust coe cients 4: SFC Optimized mass/weight parameters 5: Total and fuel weight 2: Mass/weight analysis 3: Displacements 4: Total weight Fuel weight Optimized aerodynamic coe cients 5: Lift and Drag Load 3: Low, Medium, High fidelity analysis 4: Lift Drag Final operating costs 4: Mission Analysis FIGURE 3 Multidisciplinary design analysis workflow. 3. A.B. Lambe et al., Extensions to the Design Structure Matrix for the Description of Multidiplinary Design, Analysis, and Optimization Processes, Structural and Multidisciplinary Optimization, 2012 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

14 Plan 2 Multidisciplinary Design Analysis (MDA) General framework Fixed-wing Aircraft Sizing Tool - FAST Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

15 Fixed-wing Aircraft Sizing Tool - FAST In-house multidisciplinary design analysis tool for aircraft with distributed propulsion system Specific modules : Propulsion module Geometry initialization module Aerodynamic module Mass breakdown module Global flight and performance prediction module Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

16 Fixed-wing Aircraft Sizing Tool - FAST In-house multidisciplinary design analysis tool for aircraft with distributed propulsion system Specific modules : Propulsion module Geometry initialization module Aerodynamic module Mass breakdown module Global flight and performance prediction module Input : Top level aircraft requirements (TLAR) Aircraft geometry description Propulsive parameters Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

17 Fixed-wing Aircraft Sizing Tool - FAST In-house multidisciplinary design analysis tool for aircraft with distributed propulsion system Specific modules : Propulsion module Geometry initialization module Aerodynamic module Mass breakdown module Global flight and performance prediction module Input : Top level aircraft requirements (TLAR) Aircraft geometry description Propulsive parameters Output : Mission profiles Aircraft geometry sizing Aerodynamic components characteristics Weight and balance Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

18 Fixed-wing Aircraft Sizing Tool (FAST) Preliminary design tool (ONERA & ISAE-Supaero)[4] 4 Initial input xmlfile Vapproach Npax SMreq Req. range, Cruise option Range, Mach, Altitude 0: Initiator 1:PL (0),MTOW (0),MLW (0),MZFW (0),S w (0) 1, 9æ2: MDA: FAST 2:m t f,mlwt,c t Lmax 3:MTOW t 4:Massest 9:Massest, A/C t,cl(cd) t,cl( ) t Wing sizing 2: Wing sizing 3:y wing Geometry 3: Compute initial geometry 4:A/C (0) A/C 9:A/C 4: Resize geometry 5:A/C 6:A/C CL(CD),CL( ) Masses 9:CL(CD),CL( ) 9:Masses Aerodynamics and Weight estimation 5: Compute aerodynamics 6: Mass breakdown 7:CL(CD),CL( ) 7:Masses 8:OWE Sizing mission performances 9:mf 7: Global flight 8:mf,OWEm Performance evaluation 9:MTOW 8: Update MTOW Operational mission performances 9: Operational mission

19 Fixed-wing Aircraft Sizing Tool (FAST) Preliminary design tool (ONERA & ISAE-Supaero)[4] 4 Initial input xmlfile Vapproach Npax SMreq Req. range, Cruise option Range, Mach, Altitude 0: Initiator 1:PL (0),MTOW (0),MLW (0),MZFW (0),S w (0) 1, 9æ2: MDA: FAST 2:m t f,mlwt,c t Lmax 3:MTOW t 4:Massest 9:Massest, A/C t,cl(cd) t,cl( ) t Wing sizing 2: Wing sizing 3:y wing Geometry 3: Compute initial geometry 4:A/C (0) A/C 9:A/C 4: Resize geometry 5:A/C 6:A/C CL(CD),CL( ) Masses 9:CL(CD),CL( ) 9:Masses Aerodynamics and Weight estimation 5: Compute aerodynamics 6: Mass breakdown 7:CL(CD),CL( ) 7:Masses 8:OWE Sizing mission performances 9:mf 7: Global flight 8:mf,OWEm Performance evaluation 9:MTOW 8: Update MTOW Operational mission performances 9: Operational mission

20 Fixed-wing Aircraft Sizing Tool (FAST) Preliminary design tool (ONERA & ISAE-Supaero)[4] 4 Initial input xmlfile Vapproach Npax SMreq Req. range, Cruise option Range, Mach, Altitude 0: Initiator 1:PL (0),MTOW (0),MLW (0),MZFW (0),S w (0) 1, 9æ2: MDA: FAST 2:m t f,mlwt,c t Lmax 3:MTOW t 4:Massest 9:Massest, A/C t,cl(cd) t,cl( ) t Wing sizing 2: Wing sizing 3:y wing Geometry 3: Compute initial geometry 4:A/C (0) A/C 9:A/C 4: Resize geometry 5:A/C 6:A/C CL(CD),CL( ) Masses 9:CL(CD),CL( ) 9:Masses Aerodynamics and Weight estimation 5: Compute aerodynamics 6: Mass breakdown 7:CL(CD),CL( ) 7:Masses 8:OWE Sizing mission performances 9:mf 7: Global flight 8:mf,OWEm Performance evaluation 9:MTOW 8: Update MTOW Operational mission performances 9: Operational mission

9:Massest, A/C t,cl(cd) t,cl( ) t Wing sizing 2: Wing sizing 3:y wing Geometry 3: Compute initial geometry 4:A/C (0) A/C 9:A/C 4: Resize geometry 5:A/C 6:A/C

mission performances 9:mf 7: Global flight 8:mf,OWEm Performance evaluation 9:MTOW 8: Update MTOW Operational mission performances 9: Operational mission 4. P. Schmollgruber et al.

21 Fixed-wing Aircraft Sizing Tool (FAST) Preliminary design tool (ONERA & ISAE-Supaero)[4] 4 Initial input xmlfile Vapproach Npax SMreq Req. range, Cruise option Range, Mach, Altitude 0: Initiator 1:PL (0),MTOW (0),MLW (0),MZFW (0),S w (0) 1, 9æ2: MDA: FAST 2:m t f,mlwt,c t Lmax 3:MTOW t 4:Massest 9:Massest, A/C t,cl(cd) t,cl( ) t Wing sizing 2: Wing sizing 3:y wing Geometry 3: Compute initial geometry 4:A/C (0) A/C 9:A/C 4: Resize geometry 5:A/C 6:A/C CL(CD),CL( ) Masses 9:CL(CD),CL( ) 9:Masses Aerodynamics and Weight estimation 5: Compute aerodynamics 6: Mass breakdown 7:CL(CD),CL( ) 7:Masses 8:OWE Sizing mission performances 9:mf 7: Global flight 8:mf,OWEm Performance evaluation 9:MTOW 8: Update MTOW Operational mission performances 9: Operational mission 4. P. Schmollgruber et al., Use of a Certification Constraints Module for Aircraft Design Activities, AIAA Aviation Meeting, 2017 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

22 Plan 1 Introduction 2 Multidisciplinary Design Analysis (MDA) 3 Aerodynamic Module 4 Verification and Synthesis Results 5 Conclusions and Future Works 6 References Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

23 State of the art [Weiberg 1958] [Witkowski 1988] [Veldhuis 2004] [Chatot 2014] [Agostinelli 2015]! Wind tunnel test! Twin-engine model with TE flap, high AR, thick and straight wing! Wind tunnel test! Semi empirical! Vortex Lattice Method! VLM-BEM model! Navier-Stokes model! Extended of steady actuator disk to unsteady flows! RANS-Actuator Disk model combined with the BEMT [Page 1968]! Wind tunnel test! Four propeller STOL transport aircraft! Wing of various AR [Moens 2001]! Euler and 3D Navier Stokes! Actuator Disk Model [Hunsaker 2006]! BET combined with Momentum Conservation equations! Lifting Line Theory [Ferraro 2014]! Truckenbrodt 3D lifting surface method coupled with MSES [Borer 2015]! Blade shape profile and airfoil shape using MATLAB and then fed into Xfoil! Post- Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

24 Plan 3 Aerodynamic Module Modeling Frameworks Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

25 Proposed framework model OpenVSP GEOMETRY MODELER MATLAB Update model Python Wing variables Airfoil variables Propeller variables Design changes STOP Lifting Line Theory Vortex Lattice Method MSES/Xfoil Coupling design sensitivity analysis Blade Element Theory Actuator Disk Theory Weight reduction Op#mal Optimization Lift/Drag distribution POST-PROCESSOR Applicable requirements; Take-off Climb-out Cruise performance Python / MATLAB Convergence delta C P, C L, C Di Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

26 Proposed framework model FIGURE 5 Workflow of aerodynamic module (linear) Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

27 Workflow FIGURE 6 Workflow of aerodynamic module (non-linear with high lift devices) Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

28 Propellers induced velocity Propellers induced velocity : Uniform blade loading Froude and Blade Element Theory FIGURE 7 Example of propellers induced velocities with the BET Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

29 Vortex Lattice Method Reduced computational costs ) avoid chord-wise discretization Lift curve slope fixed by distance between vortex bound and collocation point Zero-lift angle in the VLM right-hand-side term Additional mesh for defining the wake path [7] 5 FIGURE 8 Classical VLM configuration FIGURE 9 Modified VLM configuration 5. Yahyaoui, M. and al., Generalized Vortex Lattice Method for Predicting Characteristics of Wings with Flap and Aileron Deflection, International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering ; Vol. 8, num. 10, 2014 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

30 Plan 1 Introduction 2 Multidisciplinary Design Analysis (MDA) 3 Aerodynamic Module 4 Verification and Synthesis Results 5 Conclusions and Future Works 6 References Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

31 Plan 4 Verification and Synthesis Results Validation - Aerodynamic model Propeller-Wing Interaction -Linear Propeller-Wing Interaction - Non-linear with high lift device Validation - FAST Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

32 Test case - NASA TN D4448 [5] 6 TABLE 1 Specifications of the model [5]. Dimension Short wing span Medium wing span Span, m Area, m Mean aerodynamic chord, m Aspect ratio Taper ratio NACA airfoil section Sweep of leading edge, deg Root chord, m Tip chord, m FIGURE 10 Geometry model [5] 6. Page et al., Large-scale wind-tunnel tests of a deflected slipstream STOL model with wings of various aspect ratios, NASA TN D4448, 1968 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

33 Plan 4 Verification and Synthesis Results Validation - Aerodynamic model Propeller-Wing Interaction -Linear Propeller-Wing Interaction - Non-linear with high lift device Validation - FAST Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

34 C L curves for three different tools FIGURE 11 Tc = 1.0 FIGURE 12 Tc = 2.4 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

35 Lift and drag polars of medium wing span FIGURE 13 Tc = 3.8 FIGURE 14 C L C D curves for 3 Tc Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

36 Lift and drag polars for short wing span FIGURE 15 Tc =1.0 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

37 Lift and drag polars for short wing span FIGURE 16 Tc =4.9 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

38 Plan 4 Verification and Synthesis Results Validation - Aerodynamic model Propeller-Wing Interaction -Linear Propeller-Wing Interaction - Non-linear with high lift device Validation - FAST Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

39 Aircraft - Smooth configuration - Propellers on 2.5 Lift coefficient vs. angle of attack 2.5 Lift coefficient vs. drag coefficient Numerical Experimental Numerical Experimental Lift coefficient Lift coefficient Angle of attack [deg] Drag coefficient FIGURE 17 Full a/c configuration - no flaps - Tc = NACA TN 4365 [6] 7. Validation of the model for propellers induced velocity : %,cl,max = 8% No convergence for steep stall 7. Weiberg and al., Large scale wind-tunnel tests of an airplane model with an unswept, aspect-ratio 10 wing, two propellers and area-suction flaps, NACA TN 4365, 1958 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

40 Aircraft - High-lift configuration - Propellers on 3.5 Lift coefficient vs. angle of attack 3.5 Lift coefficient vs. drag coefficient Numerical Experimental Numerical Experimental Lift coefficient Lift coefficient Angle of attack [deg] Drag coefficient FIGURE 18 Full a/c configuration - flaps 40 - Tc NACA TN 4365 [6] 11. Lack of accuracy on L,max, but not on c l,max : %,cl,max = 1% 7. Weiberg and al., Large scale wind-tunnel tests of an airplane model with an unswept, aspect-ratio 10 wing, two propellers and area-suction flaps, NACA TN 4365, 1958 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

41 Plan 4 Verification and Synthesis Results Validation - Aerodynamic model Propeller-Wing Interaction -Linear Propeller-Wing Interaction - Non-linear with high lift device Validation - FAST Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

42 Test case - ATR Number of passengers 70 Range 825 NM Cruise Mach number 0.4 Approach speed kts TABLE 2 Test case ATR [1] 7 FIGURE 19 Flight mission profile Output ATR 72 FAST Wing surface [m 2 ] Wing span [m] MPL [kg] OWE [kg] MTOW [kg] MLW [kg] MFW [kg] Mission fuel [kg] TABLE 3 Test case ATR [1] 7. ATR , Feb 2017 Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

43 Output FIGURE 20 Climb profile FIGURE 21 Descent profile Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

44 Plan 1 Introduction 2 Multidisciplinary Design Analysis (MDA) 3 Aerodynamic Module 4 Verification and Synthesis Results 5 Conclusions and Future Works 6 References Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

45 Plan 5 Conclusions and Future Works Conclusions Future Works Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

46 Conclusions We have seen : Linear prediction of BVLM code in the presence of slipstream is very well predicted and validated The effects of the spanwise variation of propeller thrust on longitudinal characteristics Non-linear with high lift device aerodynamic analysis for the propeller wing interaction with a very minimum computational costs FAST has been validated for regional aircraft with conventional propulsive systems (A320 & ATR72-600) Aerodynamic module provides results good in agreement with experimental measurements for preliminary design step Both FAST and aerodynamic module are able to take multiple propellers along the wing Limitations of aerodynamic module : High dependency in 2D aerodynamic data Post-stall convergence if soft stall Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

47 Plan 5 Conclusions and Future Works Conclusions Future Works Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

48 Future Works In the future : To integrate the updated specific modules, aerodynamic, mass, etc. with FAST To continue with the MDO process focusing on the optimzation of the propeller numbers, location and size along the wing span. To expand the current aircraft model to hybrid electric configuration. Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

49 Thank you - All models are wrong, and the value of any model is only to the extent to which it supports the purpose for which it was built.- George E. P. Box Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

50 Plan 1 Introduction 2 Multidisciplinary Design Analysis (MDA) 3 Aerodynamic Module 4 Verification and Synthesis Results 5 Conclusions and Future Works 6 References Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

51 References I ATR. ATR fiche72_27.pdf/. NASA Illustration. Scalable convergent electric propulsion technology operations research (sceptor) project. https: // Available online since 11/4/15, consulted the 16/12/17. Lambe, Andrew B. and Martins, Joaquim R. R. A. Extensions to the design structure matrix for the description of multidisciplinary design, analysis, and optimization processes. Structural and Multidisciplinary Optimization, 46(2) : , A. Sgueglia S. Defoort R. Lafarge N. Bartoli Y. Gourinat P. Schmollgruber, J. Bedouet and E. Benard. Use of Certification Constraints Module for Aircraft Design Activities. In AIAA Aviation Forum, number AIAA , Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

52 References II V. Robert Page, Stanley O. Dickinson, and Wallace H. Deckert. Large-scale wind-tunnel tests of a deflected slipstream STOL model with wings of various aspect ratios. Technical report, National Aeronautics and Space Administration, Washington, D. C., Weiberg James A., Friggin Roy N. Jr.Florman Georges L.. Large scale wind-tunnel tests of anairplane model with an unswept, aspect-ratio 10 wing, two propellers and area-suction flaps. NACA Technical Note, 4365, M. Yahyaoui. Generalized vortex lattice method for predicting characteristics of wings with flap and aileron deflection. International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering, 8(10), Baizura Bohari (ISAE/ENAC) 5th Drone Garden Workshop juillet / 43

AERODYNAMIC DESIGN OF FLYING WING WITH EMPHASIS ON HIGH WING LOADING

AERODYNAMIC DESIGN OF FLYING WING WITH EMPHASIS ON HIGH WING LOADING M. Figat Warsaw University of Technology Keywords: Aerodynamic design, CFD Abstract This paper presents an aerodynamic design process