Impact of Groove Manufacturing Errors on Aircraft Skin-Friction Reduction

This study systematically investigates the effects of manufacturing errors on the drag reduction performance of micro-grooves fabricated using roll-to-roll hot embossing technology. Numerical simulations were conducted to analyze the drag reduction characteristics of spanwise micro-grooves under a 0.4 Ma incoming flow, with a focus on the influence mechanisms of groove array straightness error (δ) and bottom corner rounding error (σ) on aerodynamic performance. The results indicate that straightness errors induce periodic pressure pulsations, which disrupt large-scale turbulent structures and lead to a linear degradation in drag reduction performance. In contrast, bottom corner rounding errors modulate small-scale turbulence by altering the local curvature at the groove bottom. Positive deviations in particular cause an upward shift of the vortex core and enhanced energy dissipation, significantly impairing drag reduction. Based on these findings, an optimized processing window is proposed, recommending that the straightness error δ and bottom corner rounding error σ be controlled within −4% to 2% and −20% to 4%, respectively. Under these conditions, the fluctuation in the drag reduction rate can be confined within 20%. This study provides important theoretical insights and practical guidance for the precision manufacturing of drag-reducing micro-groove surfaces on aircraft.