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A Cellular Kirigami Morphing Wingbox Concept


Kazuya Saito, Fabio Agnese and Fabrizio Scarpa
Journal of Intelligent Material Systems and Structures published online 5 August 2011
DOI: 10.1177/1045389X11416030

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A Cellular Kirigami Morphing Wingbox Concept
KAZUYA SAITO,1 FABIO AGNESE2 AND FABRIZIO SCARPA2,
1
Japan Aerospace Exploration Agency, Institute of Space and Astronautical Science, Yoshinodai, Sagamihara,
Kanagawa 252-5210, Japan
2
Advanced Composites Centre for Innovation and Science, University of Bristol, BS8 1TR Bristol, UK

ABSTRACT: This study introduces the design and manufacturing of a wingbox based on a
cellular hexagonal morphology and produced using kirigami techniques. The wingbox is
manufactured in autoclave-cured woven Kevlar fabric using ply-cutting patterns designed
around an airfoil profile. The cellular wingbox can be completely or partially folded, providing
some shape-adapting capabilities for possible morphing applications. A numerical and ana-
lytical evaluation of the torsional stiffness of the wingbox with novel elastomeric face skins is
also performed.

Key Words: honeycomb, origami, airfoil, morphing, torsional stiffness.

INTRODUCTION structures made by truss rods and distributed actuators


for adaptive camber and trailing edge tip displacement
ORPHING wing technologies have created a con- control (Monner et al., 1999; Baker and Friswell, 2008).
M siderable interest between engineers and scientists
during the past two decades; thanks also to major R&D
Cellular wingboxes using a chiral rotational symmetry
and showing equivalent negative Poisson’s ratio (Prall
programs run by US agencies (Wlezien et al., 1998; and Lakes, 1996) have been also proposed as constitu-
Kudva, 2000). A morphing wing platform allows for tive architectures for aeroelastically tailored morphing
expanding the flight envelope of a given aircraft, provid- camber wings (Bornengo et al., 2005; Spadoni and
ing in theory a multitude of cruise operational configu- Ruzzene, 2007; Martin et al., 2008).
rations or adaptive surface controls to increase the The cellular structures used in morphing applications
performance during approach or increase maneuver have been insofar designed and manufactured using
characteristics (Powers and Webb, 1997; Monner, molding techniques, rapid prototyping (Spadoni et al.,
1999; Bowman et al., 2002; Ashley, 2003). Morphing 2006; Martin et al., 2008), or using complex composite
wing configurations have been evaluated in particular joints (Bettini et al., 2010). In this study, a novel
for micro air vehicles (MAVs), due to the intrinsic manufacturing method based on kirigami techniques is
high efficiency of any actuation authority provided to proposed to produce a prototype of adaptive cellular
deform in a continuous way high-deformable wings wingbox configuration. Kirigami is a variation of ori-
(Abdulrahim et al., 2005). A particular strand of gami, the traditional Japanese popular art of paper fold-
research in morphing wing technologies has been the ing that has received broad attention from artists,
development of compliant and flexible skins/structures architects, and mathematicians. From the engineering
for one-dimensional (1-D) morphing capabilities, either point of view, the use of origami has two significant
using cellular configurations (Murray et al., 2010; features: the capability of producing a foldable/deploy-
Olympio et al., 2010) or laminate corrugation using rec- able structure and the provision at the same time of a
tangular-type profiles (Thill et al., 2010). For more reinforcement function. The former has inspired various
information on morphing skins configurations, the types of deployable structures (Pellegrino, 2002;
interested reader can consult the work of (Thill et al., Mitsuishi et al., 2008), while the latter enables the
2008). In typical fixed-wing architecture, the wingbox is designer to create a lightweight but rigid structure
the other component subjected to innovative re-design from a single flat sheet. Unlike a traditional origami,
to accommodate continuous camber variations. One of kirigami involves paper cutting, allowing artists to
the most evaluated solutions is the use of lattice create amazing patterns on paper by combining cut
and fold techniques.

Nojima and Saito (2006) applied origami techniques
Author to whom correspondence should be addressed.
E-mail: f.scarpa@bris.ac.uk
to create integral sandwich structures and devised vari-
Figures 2—8 appear in color online: http://jim.sagepub.com ous core panels with different shapes and tessellations.

JOURNAL OF INTELLIGENT MATERIAL SYSTEMS AND STRUCTURES, Vol. 0—2011 1


1045-389X/11/00 0001—10 $10.00/0 DOI: 10.1177/1045389X11416030
ß The Author(s), 2011. Reprints and permissions:
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2 K. SAITO ET AL.

(a) (b)
Prepreg with cut

Top mold

Bottom mold
Autoclave

(c)

Cure

Figure 1. The manufacturing process of the Kirigami honeycomb.

The cellular structures are manufactured by folding a partial folding of the kirigami honeycombs also allows
thin flat sheet with periodical distributions of slits or the production of multiple hinges and adaptive struc-
punched out portions. One of the results of the applica- tures, making the cellular origami wingbox design an
tion of the origami technique includes a new type of appealing concept for morphing wing applications. In
honeycomb core (regular hexagonal) created from cut- particular, the performance of the cellular wingbox pro-
ting and folding a single paper. By using this method, posed in this study as core for a wing design based on a
Nojima and Saito (2006) also suggest the way to create NACA 2415 profile is assessed using a finite element (FE)
3-D honeycombs having various cross-sections, includ- approach. The NACA 2415 is a profile used in low-speed
ing an airfoil shape. UAVs (unnamed aerial vehicles) and MAV configura-
The cellular wingbox that is proposed in this study tions (Goraj and Frydrychewicz, 2004), and as such, it
could be entirely or partially foldable, due to the partic- has been chosen as a baseline profile for the cellular wing-
ular kirigami manufacturing process used. The use of box produced in this study. In view of the dimensions of
honeycomb fillers is quite traditional in control surface the demonstrators manufactured, the numerical models
constructions, being (for example) an integral part of the related to a morphing wing configuration are developed
design of the rudder surface of the Concorde (Hamer, for a possible MAV application using novel types of elas-
1971), trailing edges of the Airbus A300B (Anonymous, tomeric face skins developed for unidirectional morphing
1993) and of helicopter rotor blades (McCrum et al., applications (Murray et al., 2010; Olympio et al., 2010).
1997). While for commercial honeycomb constructions In particular, the torsional stiffness is evaluated to assess
the manufacturing of sections of the trailing edge of wing- the impact of using the cellular wingbox in static aero-
box requires the machining of the core, the origami elastic divergence (Bisplinghoff et al., 1983), a flight
manufacturing process allows producing a honeycomb- mechanics parameter of significant importance for
based structure with the minimum amount of required MAV design (Stanford, 2008).
material. Moreover — as it will be demonstrated in this
study—the origami (or kirigami) based process allows MANUFACTURING PROCESS
for manufacturing a honeycomb structure with an arbi-
trary shape that is not limited to rectangular extruded Figure 1 shows the basic process layout to manufac-
panels like commercial hexagonal honeycombs. The ture a composite kirigami honeycomb with regular

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A Cellular Kirigami Morphing Wingbox Concept 3

Figure 2. Cutting—folding pattern for the NACA 2415 honeycomb.

hexagonal topology (wall aspect ratio 1, internal cell The chord of the airfoil honeycomb produced is 0.13 m,
angle 30 (Gibson and Ashby, 1997). The production with a span width of 0.097 m. Figure 2(b) shows the
consists of three steps: (a) making the pattern of cutting prepreg cut with the above pattern. Dashed line cutting
and folding lines on the prepreg sheet, (b) curing the is used to make the folding lines.
sheet into a corrugated shape using a mold, and (c), The overall manufacturing process used for the wing-
folding and gluing the corrugated sheet. An orthogonal box honeycomb is shown in Figure 3. In order to make
cutting pattern produces normal flat honeycombs the corrugation on the sheet, seven aluminum trapezium
(Figure 1(a)); otherwise it is possible to create cross sec- rods (2024 alloy) are used, each obtained from hexago-
tions of various shapes only by changing the pattern of nal cross-section bars. The woven Kevlar is folded along
the cuts in the composite prepreg sheet. the specific lines around the three top and four bottom
Figure 2(a) shows the development charts for the rods, while the mold—Kevlar assembly is wrapped using
airfoil honeycomb considered in this study, a NACA polyethylene release film (Figure 3(a)). The mold is sub-
2415. The prepreg used in Kevlar woven fabric 49 sequently inserted into a vacuum bag and put in an
(914) (Wang et al., 1995, Daniel and Oshai, 2005) autoclave for 60 min and 175 C to cure the prepreg
(Young’s modulus EK ¼ 29 GPa, Poisson’s ratio (Figure 3(b)). The cured sample with the corrugate
nK ¼ 0.05, density rK ¼ 1380 kg m3), with thickness of shape is shown in Figure 3(c). The wingbox honeycomb
the sheets equal to 0.24 mm. Black lines and dashed lines can be finally assembled by folding and gluing progres-
indicate cutting and folding, respectively. In this model, sively the patterned sheets using single-component
the cross-sections are equally partitioned and approxi- epoxy glue (Figure 4(a)—(d)). Due to gluing, the hori-
mated into 17 trapeziums, as shown at the top of Figure zontal walls have a double thickness, similar to commer-
2(a). The dimensions of these trapeziums determine the cial honeycombs manufactured using the classical
cutting patterns of the chart (Nojima and Saito, 2006). staggered pattern process (Zenkert, 1997). One can

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4 K. SAITO ET AL.

Top rods

(a)

Bottom rods

Vacuum bag
(b)
Breather

A1 Plate
Release film
Prepreg
Rod Release film
Valve

Sealing tape

Aluminum plate

(c)

Figure 3. Setup of the mold and obtained corrugated sheet.

notice also that an equivalent hinge can be produced at performed using an FE approach benchmarked in
any section along the airfoil chord, simply avoiding to Scarpa et al. (2003). The honeycomb walls are modeled
glue a specific section of the corrugated core (Figure 4(b) using SHELL63 quadrilateral elements from the
and (c)). ANSYS commercial FE code (ANSYS, 2008). Each
shell element has six nodal degrees of freedom
(DOFs) (three translations and three rotations), with
NUMERICAL EVALUATION OF THE an average dimension equal to 1/8 of the length of
TORSIONAL STIFFNESS the oblique wall. The dimensions of the FE model
are the same as that of the prototype produced. The
An evaluation of the torsional stiffness GJ of the solid model of the origami airfoil honeycomb is
cellular honeycomb wingbox completely folded is obtained through a Boolean operation, where a

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A Cellular Kirigami Morphing Wingbox Concept 5

(a)

(b)

(c)

(d)

Figure 4. The folding process for the airfoil honeycomb.

classical hexagonal honeycomb panel with uniform the span of the wingbox. The torsional stiffness of
extrusion along the thickness chord direction is inter- the cellular wingbox is then obtained using the classical
sected by a volume with a constant cross-section that is relation GJ ¼ Mt/ (d/dz). A similar approach is also
equal to the NACA 2415 airfoil extruded along the taken to assess the effect given by the presence of skins
wingspan direction (Figure 5(a)). All the DOFs present over the cellular airfoil (Figure 5(b)). To this extent,
at one end of the wingbox are clamped, while the rota- the material of the skin considered is 10 A elastomer
tional DOFs around the z-direction (corresponding to (Murray et al., 2010) (Es ¼ 0.138 MPa, ns ¼ 0.45,
the wingspan axis) are coupled together at the opposite rs ¼ 1100 kg m3), while the uniform thickness of the
wingbox end. At the same location, a unit torque Mt is skins is 2 mm. The boundary conditions applied to cal-
applied at a single central node of the cross-section. culate the torsional stiffness are the same for the pure
After solving a linear static problem, the output rota- cellular wingbox configuration.
tion yt is obtained, and an approximation of the tor- The value of GJ for the cellular airfoil configuration is
sional gradient calculated as d/dz & yt/b, where b is 0.63 N m2 (Figure 5(a)), while the presence of the skins

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6 K. SAITO ET AL.

Figure 5. Total deformation patterns under pure torsion for: (a) airfoil honeycomb section and (b) cellular wingbox with face skins.

provides only a slight increase of 3% to the stiffness in The above simulations are valid for the wingbox with
question (0.64 N m2, Figure 5(b)). From these simula- no hinge present. The presence of an embedded hinge at
tions, it is evident that the cellular wingbox not only specific discrete locations of the airfoil does tend to
maintains the aerodynamic shape, but contributes criti- decrease the overall torsional stiffness of the airfoil. A
cally to the torsional stiffness of the entire wingbox. The demonstration of this fact can be made from examining
load-bearing capabilities of the cellular wingbox become a simplified (and symmetric) version of the airfoil, as
very appealing when extremely flexible skins are used, illustrated in Figure 6.
providing the control for the divergence speed in Let us consider the airfoil made with a skin of con-
static aeroelastic cases. In terms of mass distribution, stant thickness and homogeneous material. From
the airfoil wingbox of this study has an overall weight Bedt—Batho theory (Howe, 2004), ignoring the the influ-
of 10.7 g, which constitutes 15% only of the total weight ence of the internal structure of the wingbox, the tor-
related to the wingbox with the 10A elastomer skins sional stiffness of the airfoil is proportional to Aw =P2w ,
(70.1 g). where Aw and Pw are, respectively, the cross-sectional

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A Cellular Kirigami Morphing Wingbox Concept 7

(a) (b)
A0 hk

h0

Ck
hk
P0
Cn

Figure 6. (a) Simplified airfoil configuration with discrete possible hinge locations and (b) artificial tab at location k created by a rotation  of the
corresponding kirigami-folded section.

area and perimeter of the wingbox. If one assumes that 6


the morphing part of the airfoil is represented by a tri-
angular component made of n sections of length ck each
(corresponding to the folds of the kirigami structure), 5
the area of the undeformed wingbox is represented by: Torsional stiffness loss (%) θ = 2°
4 θ = 5°
k h0 ck θ= 10°
Ab ¼ A0 þ ð1Þ
2 θ = 20°
3 θ = 50°
where A0 is the area of the fixed portion of the morphing
section and h0 the maximum thickness of the fixed part
of the airfoil. The perimeter Pb can be approximated as 2
follows:
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi 1
Pb ¼ P0 þ h20 þ 4 n2 c2k ð2Þ
0
From Equations (1) and (2), the torsional stiffness of 1 2 3 4
k
the undeformed morphing wing section can be calcu-
lated as Ab =P2b . At a specific section k ¼ 1, . . . , n  1 Figure 7. Torsional stiffness loss for a kirigami-based symmetric
(with k ¼ n at the trailing edge), the thickness of the morphing wingbox.
Note: The simulations have been carried out for A0 ¼ 2740 mm2,
morphing part of the airfoil is hk ¼ h0 (n  k)/n. An P0 ¼ 89 mm, ck ¼ 25 mm, and n ¼ 5.
equivalent tab angle y induces an increase of the perim-
eter of the skin equal to hky and an augmentation of the
area of the wingbox cross-section of h2k =2. These rela- From Equations (3) and (4), it is possible to define the
tions are valid assuming the skin is stretched completely torsional stiffness loss compared to the base unmorphed
elastically and is subjected to loading prior to tensile configuration as:
failure. After some mathematical manipulations, the
perimeter Pm and area Am of the morphed wingbox at

Am P2b
the kth location can be represented as: TSL ¼ 1  ð5Þ
Ab P2w
 qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi 
1 Figure 7 shows the value of TSL for a configuration
Pm ¼ P0 þ h20 þ 4 n2 c2k þ h0 ðn  kÞ ð3Þ similar to the kirigami morphing box manufactured in
n
this study (n ¼ 5, constant ck cut-fold distance of 25
1     mm). The length of the fixed part of the wingbox has
Am ¼ h0 ck n3 þ n2 2 A0 þ h20   2 h20  k n þ h20  k2 been assumed to be equal to one-fourth of the total
2n
chord c. For all the tab angles y considered, the highest
ð4Þ
torsional stiffness loss is observed when the hinge is

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8 K. SAITO ET AL.

(a)

(b)

(c)

Figure 8. Variable equivalent tab angle for a trailing edge obtained through partial folding of the honeycomb wingbox.

created at the root of the fixed portion of the airfoil response of the wingbox when considering divergence-
section, with a maximum loss of 6% for y ¼ 50 . The related problems, where a non-linear behavior of the
loss is decreased by more than 50% when only the last wing with possible contact between the split blocks
fold line (k ¼ 4) is used for the morphing. However, could occur (Bharti et al., 2007).
these results are not conservative. As mentioned
above, for the kirigami cellular wingbox, the honey-
comb-based configuration provides 97% of the overall DEMONSTRATION OF ADAPTIVE
torsional stiffness for the airfoil. The creation of a CAMBER LAYOUT
hinged configuration splits the cellular core into two dif-
ferent blocks, and therefore, the torsional stiffness of the The origami manufacturing process allows to produce
hinged kirigami wingbox would be lowered compared to an artificial hinge in the wingbox, avoiding gluing the
the unmorphed configuration. From a purely static corrugated sheet at specific positions. Figure 8 shows the
point of view, the hinges should be considered also in effect of ungluing the airfoil at 25% of the chord from
terms of non-linear mechanical analysis, making, there- the trailing edge tip. The different positions of the arti-
fore, the design and simulations related to the kirigami- ficial tab created by simple ungluing of the wingbox are
based wingbox dependent on issues highlighted for com- fixed with metal clips in the demonstrator at 5
pliant cellular mechanisms (Mehta et al., 2009; (Figure 8(a)), 20 (Figure 8(b)), and 70 (Figure 8(c)).
Ramrakhyani et al., 2009). Moreover, the presence of The artificial hinge capability indicates that the origami
embedded hinges provides also a complex mechanical manufacturing process could be used to develop

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A Cellular Kirigami Morphing Wingbox Concept 9

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