Structural Analysis and Testing of a Flexible Rudder Using a Cosine Honeycomb Structure

Abstract

This paper introduces a new type of flexible rudder surface based on the cosine-type zero Poisson’s ratio honeycomb to enhance the adaptive capabilities of aircraft and enable multi-condition, rudderless flight. The zero Poisson’s ratio honeycomb structure exhibits exceptional in-plane and out-of-plane deformation capacities, as well as a high load-bearing capability. To investigate the deformation characteristics of flexible rudder surfaces utilizing cosine honeycomb structures, this study undertakes a comprehensive investigation through finite element simulation and 3D printing experiments. Moreover, this study analyzed the impact of honeycomb parameters and layout on the deflection performance and weight. The flexible rudder surface, fabricated from nylon, achieves smooth and consistent chordwise bending deformation, as well as uniform spanwise deformation within a tolerance of ±25°, and the maximum equivalent stress observed was 31.99 MPa, which is within the material’s allowable stress limits (50 MPa). Finite element simulation results indicate that once the deflection angle of the rocker exceeds 15°, a discernible deviation arises between the actual deflection angle of the flexible control surface and that of the rocker. Furthermore, this deviation escalates with increasing rocker rotation angles, and this discrepancy can be mitigated by augmenting the number of cosine honeycomb cells within the flexible rudder surface. Finally, a prototype of the flexible rudder surface was successfully produced using 3D printing technology, and the experimental results confirmed the deformation behavior, aligning with simulation outcomes with a deviation of less than 20%. These findings confirm the effective deflection performance of the designed flexible rudder surface, highlighting its potential application in small unmanned aerial vehicles.