Design Optimization of Interfacing Attachments for the Deployable Wing of an Unmanned Re-Entry Vehicle

Re-entry winged body vehicles have several advantages w.r.t capsules, such as maneuverability and controlled landing opportunity. On the other hand, they show an increment in design level complexity, especially from an aerodynamic, aero-thermodynamic, and structural point of view, and in the difficulties of housing in operative existing launchers. In this framework, the idea of designing unmanned vehicles equipped with deployable wings for suborbital flight was born. This work details a preliminary study for identifying the best configuration for the hinge system aimed at the in-orbit deployment of an unmanned re-entry vehicle's wings. In particular, the adopted optimization methodology is described. The adopted approach uses a genetic algorithm available in commercial software in conjunction with fully parametric models created in FEM environments and, in particular, it can optimize the hinge position considering both the deployed and folded configuration. The results identify the best hinge configuration that minimizes interface loads, thus, realizing a lighter and more efficient deployment system. Indeed, for such a category of vehicle, it is mandatory to reduce the structural mass, as much as possible in order to increase the payload and reduce service costs.