How to design and make humpback whale inspired surfboard fins

XFLR5 does it. You don’t need to actually be able to handle the equations, I can’t, but understanding the principles and terminology of aerodynamics is not too hard to learn.

X5 can analyse a complete plane or hydrofoil, including stability analysis, but you don’t need to learn this if you just want to analyse and compare 2D foils. Beating the best existing foils is doable but takes many hours, I am building a collection of foils for surfing that over perform the best foils one at a time. It can work for air or water as a medium by changing some values. It has been used by some America’s Cup teams, including some title holder. The whale bump hydrofoil was designed in X5 and it behaved as expected, I wanted it to be able to take off at low speed, lifting 70gk at 3 m/s and 15 deg AoA and it did judt that. Then it can cruise at over 10 m/s at lower AoAs.

There’s some good tutorials on youtube and while full plane behavior analysis is more work, getting to the point to manipulate foils is quite quick. But be warned, you might stay stuck to your computer for hours, it’s addictive.

To get you motivated here’s my E168 contender, exact same thickness at the same position but way more lift, stall delayed by 2 degrees, wider drag bucket. Trade off is a little more drag at low angles of attack, which rarely occur in surfing even when going down the line. 

Are you abbreviating XFLR5 or is this another software?

Sure looks like a rabbithole that could swallow me for years to come…

Could this software compare a flanged G-Whale fin vs a non-flanged fin? 

Same software.

It would certainly give different results but I don’t think it can analyse the tubercle effect accurately. X5 is not CFD but it is consistent with tunnel tests for “normal” wings. I studied delta wings and it looks like the vortex lift was taken into account, but for the complex 3D flow over tubercles even CFD is pushed to it’s limits. You can’t import 3d models into X5, you have to design them inside the software and the method is tedious for anything complicated. Also you can’t model the board, it is really dedicated to wings.

For the tubercles hydrofoil I used the software to find the right wing planshape, span, chord, twist, foil etc. but without the tubercles. I added them latter in CAD knowing that they could only improve stall at the cost of a little more drag, if done within reasonnable limits (freq, amplitude).

Here’s some eye candy, it is your G-Whale 7 (E168) at 0 degree AoA at 5 m/s in Autodesk Flow Design. It doesn’t count as data, but it gives an idea of what is going on around the bumps, and it is tasty food for thoughts :slight_smile:

I don’t know how to interpret the picture, but I sure like it!

My 

Here is a fin I cut out recently. It has a non-tubercled brother that hasn’t been cutout yet. The outline is based off a supermarine spitfire wing. Still using plywood, but the plys look pretty cool on this one.


 

Cool, Swaylocks is the hub of tubercled fins research :slight_smile:

Since this thread is about design, I’ll say something about the geometry of the tubercles. The tubercle effect varies in function of the amplitude and frequency of the sinusoidal LE in relation to the chord length. The effect is small when the bumps are tiny and more pronounced with bigger ones.

But there is an upper size limit at which the effect becomes detrimental as it generates too much drag. The maximum is about 20% of the chord length. On the lower limit, under an amplitude of about 5% they barely influence the fin’s behaviour. 10 to 20% of the chord length seems to be the sweet window.

Too big bumps generate vortices that will need a bigger portion of the chord length to develop and will “run out of fin”, so some of the drag is not transformed in better after-stall performances. Too small bumps and the vortices are too small and carry less energy, so they can’t keep the boundary layer attached much beyond the normal stall angle of a given fin.

Basically you trade a little bit of performance at low AoA for much better performance beyond the stall angle. Bigger bumps smoothen the stall more while reducing lift and adding drag to do so. Smaller ones will have a more subtle effect on the stall.

So you can tune in the amount of tubercle effect that you want. Small bumps if you still want to be able to have a marked but not too sudden fin release, while having virtually unchanged performance before stall. Big bumps for a super smooth stall that you’ll be able to recover from, without having really completely stalled. 

There’s also an effect of the frequency of the sinusoidal, more pointy peaks or flatter ones behave differently. Also the type of foils, but we’ll keep that for later, I’m not sure I made sense in the above already.

So this last fin seems to be at the upper amplitude to chord limit. Beyond that the drag trade-deal is getting less interesting. This fin should have a smooth stall, very much like the GW7.

I’ll be honest, I didn’t put much thought into the size, shape, or number of tubercles. I just used what looked right for the outline I was using. 

When you say there is an amplitude sweet spot between 10-20% chord length, are you referring to the chord length of the airfoil or the chord length of the fin outline itself? 

I’ve tried some of MrMik’s harftubs with more tubercles, I believe it was 15 or 20 vs the 9.5, once. I kept thinking I was dragging kelp the whole ride, only to flip the board over after kicking out,  and finding nothing on the fin or nearby in the water.  The next harftubs that arrived had 6.5 larger turbucles and this felt faster and slightly less forgiving, but overall better.

 

These impressions underfoot on boards I am very familiar with, seems to be opposite of the science. with 6.5/7 larger tubercles feeling less draggy and less forgiving than 9.5 tubercles.

 

Then I tried the slightly deeper Gwhale fin with 7 tubercles and rarely if ever rode another harftub again, I think the only time was dragging the video camera behind it. 

 

I’ve a whole bunch of early  harftub pure PLA fins never tested, as the GW7 was just so good, but it is even higher aspect ratio, so not directly comparable to harftubs regarding tubercle size and number.

  Though I’m willing to try a GW9 or a GW5, or a spit fire, Though I am not really racking much water time these days.

 

 

 

 

 

Interesting, it could be that the fins with more tubercles were falling under the 10% chord ratio, or some other interactions, like the foil profile used (smaller tubercles don’t work very well with thick foils). Or the angle of the slope between peaks could be the culprit. It seems that you prefer large amplitude, low frequency tubercles, which makes sense. I am surprised that you find them less forgiving though and also the more draggy feeling of the smaller tubercles. I would be very interested if you could find the time to post pics of the very best and worst fins that you tried. Just a few, like the 2 worst and 2 best with a short description of your impressions.

I am trying to extract rules of thumb out of more than 60 scientific papers, my own simulations and actual surf testing. While there seems to be a consistency in the variation of the tubercle effect in relation to its geometry, there are also configurations that jump out of the pack, in good or bad. There’s so many variables, some tubercles will show an advantage at very specific AoAs or Reynolds numbers. The thickness of the foil also changes which tubercles configuration is more favorable. Anyway, it is obvious that the idealized conditions of the studies are not the same as real surf. But I think some sort of general rules can be found while the final verdict will obviously be found in actual surfing conditions.

The chord length of the airfoil at a given position along the span. In other words, let’s say that the chord length of the fin at a peak is 100%, so if the the chord length at the next through is 80% that, we have a 20% chord lentgh amplitude. This is just an easy way to characterise the bumps for the sake of finding some sort of general rules. Then there’s the frequency (distance between peaks) but for now it seems that most designs, including yours, intuitively choose a frequency of around twice the amplitude, which is a good zone to be in.

Again, I know that real life surfing is the only judge but I think general rules can be helpful to devellop new fins. Just like there are general rules about rocker, toe-in etc. Of course these rules interact between each other in a real board and can give all kinds of weird results in some cases. I just get stoked at the mental exercise of visualizing flow over different configurations and how the performance envelop is morphing with the geometry.

The impressions formed with more vs less tubercles were all on the older harftub fin design.

  It was a while ago, I did write down my impressions soon after surfing them, usually within hours, and will have to find dig through a lot of old Emails between MrMik and myself, as my memory of waves rode and impressions of various fins from three years ago is quite faded. Once I rode the GW I was done with the harftub, nearly having a panic attack when it started to break and I had no backup GWhale.  I gave the best harftub 6.5 to Zack Flores, who said it went unreal in  some Salina Cruz pointbreak on his midlength.  Have not seen him in a long time, but have pics of it on my external hard drive somewhere, and MrMik seems to keep quality records of specific fins, when I can provide the dates printed into the fin bases.

 

The GW’s variables have been the thickness, and the flex, both lateral and rotational, flanged base or unflanged, same planshape.  I don’t think it ever occurred to me to inquire for a different size and shape of the tubercles of the GW7, as it never felt like it was lacking anything just subtle differences of great speed and response.  The fatter fins turned better and were more forgiving but did not have the turbo button, the thinnest fins straight line trim quicker with turbo, and less forgiving, requiring more precision initiating and through turns.  I recall saying if I were rusty or at a slower peeling wave wanting to do lots of harder turns, I wold want the thickest Gwhale until I scraped off the rust, then the thinner fins for that thrilling 5th gear turbo spark on more down the line waves.

 

  The most flexy fins felt the worst to me, but the stiffest was not quite as good as the second stiffest.  The one fin with a very rotationally flexy filament was way too weird.  Weird through the initial loading of it, and uncontrollable as to when the flex would unload where it would unset the rail and change the line chosen.

  The experimentation tapered off in this area, as it became too difficult to really notice the  extremely subtle differences when a fin would deflect 14mm or 18mm when i’d apply 10Lbs of load to the second highest tubercle in my flex testing jig, and when I’d not really be able to perfectly replicate how one fit  in my worn stretched fin box compared to the next in terms of how much the fin base flexed in the box itself.  

 

Right now the GW fin in my longboard is one of the stiffest and certainly the strongest with the highest amount of carbon bars cross section epoxied to the interior reaching as close to the tip of the fin as possible, to the best of my abilities, ensuring the best possible adhesion of pultruded carbonbar to PLA.

  I’ve made spacers before and behind the fin to fill in the fin box  holes as there is no need to move the fin up or back anymore.  Interestingly when swinging the boards tail underwater, filling in the voids in the box before and after the fin added resistance to swinging the board’s tail underwater, making it a more effective paddle.  Can’t really tell any difference up and riding, though it should feel even quicker.  

 

I’ll see what I can compile from my Emails with MrMik and find, or take new pics of the relevant 2 best and worst harftubs.

Cranked out another one. I like the shape, but the last one seemed a little too small for the longboard I was using it in. I also did a resin halo. Halo didn’t come out the best. I think I used too much catalyst and it cracked a bit.

Was watching a  PBS/public Tv Nature show just now.

animals with cameras

 

They show some Penguins hunting anchovy with a camera attached behind the head of one penguin.

The wing of a penguin, bears a striking a resemblance to the  humpback pectoral fin, but more streamlined.

 

Notice the weird trailing edge striations in the direction of water flow.

 

A wing, that evolved to be functional, only when underwater. Hmmmmm. 

As far as Biomimicry goes, this seems like a good candidate. 

It also looks to be the same general depth/area,  as a surfboard fin.

 

They do the same hunting tactics as Humpbacks, dive under them and surface through them from below.

 

But these guys tuck air deep inside their feathers before diving, and as this air expands as they surface through the bait ball, it expands and the extra buoyancy rockets them to the surface.  No video of this, but that air water interface around the wing, like surfboard hull and fin is also a good parallel to our intended usage.

 

What If Greenough got mesmerised by one of these, instead of the tailfin of a bluefin tuna?

 

Wonder what the foil resembles…

Hope this video loads for those outside the US.

https://www.pbs.org/wnet/nature/animals-cameras-episode-1/15926/?button=fullepisode

 

Underwater video starts about 38:30

 

These screen shots taken about 41:00.


Super-interesting1

I’m waiting for VPN magic to allow me to watch the videos.

A few weeks ago, I spent a night a Sea World Resort. FMDACMM

But is was a clear lull in Covid transmissions, and there have been no cases in several weeks in my state. Good opportunity to keep the missus happy!

What stood out to me at Seaworld were the penguins. I watched them twice, first time they obliged, second time no such luck. Family oblgations tore me away from the little critters swimming around less than 1.5m from me, blatantly dis-regarding any social distancing rules.

( I have to admit that the rays where also most amazing, they are magic flying carpets with a tail twice their body length, most likely a sensory organ to analyse the vortex…

OK, I stop waffling, the video seems to be running, now that I have moved to Carolina or some such…

One of the most insight-provoking videos I have ever seen was the one where a penguin dives deep under the ice (carrying a camera), then cruises at depth, hidden in the total blackness, like a falcon hidden in the total brightness of a sunlit sky, then the penguin ‘freefalls’ upward to assassinate an unsuspecting ice-fish. 

 

Do not skip the meerkats, or anything, if you want to learn how fins work…

Looking good, curious to know what foil you are using ?

Yes, impressive how the planshape is very similar to the humpback, including the cutaway near the body. I wonder how much the cutaway is shaped by hydrodynamics or for ease of movement. Probably a bit of both. Some research paper indicates that the foil is close to NACA 63018. 18% thick with max thickness at around 33% of chord length. At the cutaway the foil’s thickness goes up to 40% chord because of the bones but the actual thickness is similar the rest of the flipper.The penguin’s flipper seem to be smoother, with a more consistent foil than the whale.

These are fat foils, 13% thick is the max I have used for a single fin yet. 

The cutaway would seem to be a requirement in order to reduce aspect ratio at higher speeds, but could also reduce interference drag.  Penguins not having a tail for thrust, means their wings are also the propulsion, not just passive directional changers like pectoral fins.

 

The trailing edge striations are interesting too, but no Idea how deep they are, or if they are visual only and not actually ribbed.

 

I was thinking a set of these pengwing  rail fins a @ ~7" inches deep with cambered foil, would be neat to try.  I busted out a pencil and white cardboard yesterday and drew a few from memory, failing badly to achieve anything which ‘looked right.’  and failing that, even similarly to a peng wing.

 

If  designed for use as a single fin for my longboard, depth would likely need to be around 12".  Initially I thought the high aspect fins looked too small, but they have more drive than my significantly larger dol-fin and way less drag.

Looks like the Pengwing would be even more so, even at ridiculously thick and deep.

 

 

 

 

I don’t remember for sure off the top of my head, but it was either the e168 or e169. I can check later when I get back to my computer. It turned out way better than I thought, but still needs some work. I am really stoked to try it out.

Stop tempting me…

These are drawn from your screen capture. Smoothed the curves a bit to remove “biological randomness”. Then compensated for the camera angle. From left to right I added some sweep which made the bases wider. At 7 inches deep the bases are respectively 1.5, 2 and 2.25 inches. At 12 inches deep the bases are around 3.5 inches.

Once we get the planshapes right I’ll model the complete Pengwing Thrusters Set and the single. All planshapes don’t have to be the same, the sweep can varie between the side and center fins. Are you thinking about a cambered foil at 18% thickness for the side fins ? Give me some hints about the foil you see, lotsa camber ?

I think the side fins should have a bit of curves to them as I don’t think the penguins ever keep them fully flat. And I’ll bet they add a bit of twist toward the tip, like 2 or 3 degrees because they surely feel the tip vortex.

That break in the leading edge’s outline, with mini ish tubercle with lower aspect ratio to tip afterwards,  is what i was attempting to draw the other night when infused with beer