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Thread: Esterel 45

  1. #11
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    Default Re: Esterel 45

    Drawn the Servo Arm version with Savox1256TG.
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  2. #12
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    Default Re: Esterel 45

    For those who are interested, here the PDF file for the Esterel 45 (v.9) Shadows to scale 1:1 directly printable
    Attached Files Attached Files

  3. #13
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    Default Re: Esterel 45

    Square carbon tubes 4x4x3x1000mm received. 10g each Details for the Fin trailing edge using aluminum sheet. List of materials for Fin assembly - 107g with only 2 square tubes before bonding. +10g for 3 square tube.
    Measurement of carbon square tube indicate that the inner dimension is 3.1mm and not as assumed 2.6mm.
    This imply a loss of bending strength. 3 square tubes may be used !
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    Last edited by claudio; 08-17-2017 at 12:20 PM. Reason: added drawing

  4. #14
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    Default Re: Esterel 45

    Quote Originally Posted by claudio View Post
    For those who are interested, here the PDF file for the Esterel 45 (v.9) Shadows to scale 1:1 directly printable
    Are these your "definitive so far" versions Claudio?

  5. #15
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    Default Re: Esterel 45

    Yes, only the Fin is still under evaluation. Spacers of 0.25mm added.
    Fin construction start tomorrow.
    According to my calculations with the existing formulas, the 54cm long Fin should be more stiff than a carbon tube of 8x6mm 54cm !
    Actually, before epoxy bonding, see materials updating is for 94g. Only 2 tubes used instead of 3.
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  6. #16
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    Default Re: Esterel 45

    Fin assembly started with 4x4mm carbon square tubes and brass rods alignment. Mounting support 8mm glass plate. Added 3 carbon tube spacers.
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    Last edited by claudio; 08-19-2017 at 06:38 AM.

  7. #17
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    Default Re: Esterel 45

    some pictures of the work progress.
    Some resin voids found on the opposite side as expected.
    The voids should be filled up with the glass spacers bonding.

    I will explain why the use of glass spacers !
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  8. #18
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    Default Re: Esterel 45

    About the Fin Design:
    The starting point was to obtain a Fin weighting less than 120g in order to satisfy the Esterel 45 construction Budget.
    I was told about Helicopter Blades, but found too heavy for the size needed. May be someone have better experience on the subject.
    The Fin was also supposed to have a Chord thickness below 7%, better if 6.5%
    I discovered on the market the availability of carbon square tubes that are in principle mechanically stiffer than carbon round tubes.
    The Fin is 80mm wide therefore : 80 x 6.5% = 5.2mm.
    Thus the Fin thickness should be close to 5.2mm.
    The Fin is actually composed of carbon square tubes 4x4mm plus glass spacers plus Fin carbon sheet lamination, for a total of 5.5mm of thickness.
    5.5/80 = 6.8% that is lower than 7% but above 6.5% as indicated above.
    The figure below show the 'step by step' design evolution.
    Threaded brass rods are inserted between the two tubes. The rods will adds some local strength only.
    The material necessary was weighting 94g before bonding and shaping adjustments.
    Carbon sheets 540x80x0.5 mm weight 55g.
    In spite of theoretical calculations I have no idea of what will happen !
    Off course one may think about the use of 3 carbon square tubes to get more stiffer construction similar to a carbon tube of 10x8mm. It will adds about 13g only !
    This is theory since the material used are not a monolithic assembly, but rather a multiple material assembly including epoxy resin, therefore some lower strength is expected.
    The Bulb weight is 3000g
    Square tubes, also available, are 6x6mm, too big for the purpose, 5x5mm not seen

    I recall that a Carbon round tube 8x6mm has a W=34.33
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    Last edited by claudio; 08-20-2017 at 08:18 AM. Reason: added text

  9. #19
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    Default Re: Esterel 45

    Assuming that this Fin Design will not support 3kg bulb within an acceptable flexion limit, there is the option consisting of the introduction of 2 additional carbon square tubes or even round at small weight increase still within the expected 120g. This morning after night thinking I decided to assembly the Fin with 4 square tubes according to this drawing.
    The brass rod is positioned at 35% from leading edge.
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    Last edited by claudio; 08-21-2017 at 05:55 AM. Reason: drawing update

  10. #20
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    Default Re: Esterel 45

    Bonding in progress !
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