Optimized Structural Design of a Reciprocating Wing for the Reciprocating Airfoil (RA)-Driven Vertical Take-Off and Landing (VTOL) Aircraft

The development of unconventional and hybrid unoccupied aerial vehicles (UAVs) has gained significant momentum in recent years, with many designs utilizing small fans or rotary blades for vertical take-off and landing (VTOL). However, these systems often inherit the limitations of traditional helicopter rotors, including susceptibility to aerodynamic inefficiencies and mechanical issues. Additionally, achieving a seamless transition from VTOL to fixed-wing flight mode remains a significant challenge for hybrid UAVs. A novel approach is the reciprocating airfoil (RA) or reciprocating wing (RW) VTOL aircraft, which employs a fixed-wing configuration driven by a reciprocating mechanism to generate lift. The RA wing is uniquely designed to mimic a fixed-wing while leveraging its reciprocating motion for efficient lift production and a smooth transition between VTOL and forward flight. Despite its advantages, the RA wing endures substantial stress due to the high inertial forces involved in its operation. This study presents an optimized structural design of the RA wing through wing topology optimization and finite element analysis (FEA) to enhance its load-bearing capacity and stress performance. A comparative analysis with existing RA wing configurations at maximum operating velocities highlights significant improvements in the safety margin, failure criteria, and overall stress distribution. The key results of this study show an 80.4% reduction in deformation, a 43.8% reduction in stress, and a 78% improvement in safety margin. The results underscore the RA wing’s potential as an effective and structurally stable lift mechanism for RA-driven VTOL aircraft, demonstrating its capability to enhance the performance and reliability of next-generation UAVs.