Low altitude uav aerodynamic analysis and prototype manufacturing

In this thesis, the aerodynamic design, structural analysis, material selection, and prototype manufacturing process of fixed-wing unmanned aerial vehicles (UAVs) operating at low altitudes are addressed through an integrated engineering approach. The study focuses on the development of an original UAV design aimed at enhancing domestic production capabilities, particularly within the context of micro and mini-class UAVs, which are increasingly significant in the national defense industry. In the initial phase of the research, theoretical fundamentals regarding low-altitude flight dynamics, aerodynamic forces, and lift-drag balance are discussed. Based on these principles, critical design parameters such as wing profiles, fuselage geometry, and motor configuration are defined. Flight performance parameters including wing angles and surface areas are analyzed using CFD (Computational Fluid Dynamics) software such as ANSYS Fluent. The aerodynamic optimization process employs experimental design methods including Taguchi and Response Surface Methodology (RSM), while ANOVA analyses are conducted to evaluate the statistical significance of these parameters. In the manufacturing phase, carbon fiber-reinforced composite materials are selected due to their low density and high strength properties. The prototype is produced through a series of processes including mold fabrication, vacuum infusion, mechanical assembly, and electronic system integration. Static load tests, center of gravity (CG) measurements, and pre-flight system checks are conducted, followed by flight tests evaluating takeoff, cruising, maneuverability, and landing performance. As a result, the design was validated as airworthy, and based on the findings, several recommendations are presented for the design, production, and testing of domestically developed UAV systems. This thesis offers a cost-effective, optimized, and locally produced UAV solution, making significant contributions to both the literature and the aerospace industry through the holistic application of engineering principles.