Design and experimental validation of 6 component wind tunnel force balance

Fluid mechanics, a crucial domain in engineering science, underpins numerous engineering principles and necessitates the resolution of the nonlinear and intricate Navier-Stokes equations for flow analysis. Owing to the complexity of these equations, experimental and numerical methodologies are important for investigating the influence of fluids on objects and for precise measurement of these effects. In this area, wind tunnels are often used to create a controlled flow setting that is important for studying how three-dimensional models behave in flow and learning about flow characteristics. The aim of this study is to design a force balance mechanism capable of measuring forces along six axes for use in wind tunnels. This mechanism will precisely measure lift, drag, and lateral forces, as well as pitching, roll, and yaw moments, on models placed in the test chamber of subsonic wind tunnels. A Stewart Platform-type balance mechanism with high crosstalk sensitivity will be used in the design process. The experimental apparatus will accurately quantify the lift, drag, and lateral forces of three-dimensional models, in addition to the torque produced on each axis. The system orientation can be readily altered by computer commands and buttons, with measurement data transmitted to concurrent digital displays and logged over time. This feature will facilitate the generation of significant graphs post-experiment and enhance the precision of data utilized in scientific research. During this study, various force balance mechanisms in the literature were investigated, and a unique design approach was adopted. A system inspired by the Stewart platform, yet possessing a different degree of freedom, was developed for use within an experimental chamber. Designed for this system, a control algorithm allows the electromechanical components to run in line with the algorithm, therefore enabling the user to change the orientation of the model housed within the wind tunnel chamber. Load cells integrated into the system enabled the measurement of aerodynamic forces acting on the model. Sensor outputs were analyzed and converted into meaningful force components. This method ensures the accuracy of force measurements and increases the reliability of experimental results. Following the research, the system was exhaustively assessed. System accuracy was found by extensive study and assessments using position control and measurement. Multiple tests were conducted on the system to see whether it could remain still or move under control criteria. Calibration of sensors and control systems has been carefully done to minimize the margin of error in practical applications.