Professional Documents
Culture Documents
Design Optimization of Drone Propeller: Project Title
Design Optimization of Drone Propeller: Project Title
Design Optimization Of
Drone Propeller
SCHOOL OF ENGINEERING
1
COURSE: WSQ SPECIALIST DIPLOMA IN PRECISION ENGINEERING
(ADDITIVE MANUFACTURING)
PROJECT MEMBER(S):
Proposed by:
SCHOOL OF ENGINEERING
2
SUMMARY
Surface model Solid model Engineering simulation with surface model Then
Engineering Simulation with solid model 3D print Design test Fixture Test and
collect data Compare actual with simulation result.
SCHOOL OF ENGINEERING
3
ACKNOWLEDGEMENTS
Anna Flessner
Engineer, Community Manager at SimScale GmbH
Sneharaj Malankad
Senior Lecturer, at Nanyang Polytechnic
SCHOOL OF ENGINEERING
4
TABLE OF CONTENTS
Summary 3
Acknowledgements 4
Conclusion 19
Appendix 20
Gantt Chart 21
References 22
SCHOOL OF ENGINEERING
5
CHAPTER 1
1.0 AERODYNAMIC OF DRONE
Propeller need to generate force called lift. Both Newton 3rd law of motion or Bernoulli’s
principle can be use to explain how lift is generated.
Fig 1.1 Newton 3rd law, the propeller pushes a column of air downwards to create an opposite but equal trust
force upwards.
Fig 1.2 Bernoulli’s principle. As speed of air increases, pressure is reduced, thus creating a net force (lift)
upward.
SCHOOL OF ENGINEERING
6
CHAPTER 2
2.0 DESIGN CONSIDERATION FOR PROPELLER
The propeller is a spinning wing, Air moves over the surface of the airfoil generating lift.
But for a quadcopter, a small motor rotates the airfoil at high speed and the propeller
transform the rotory power to upward lift. Unlike an aircraft wings, the propeller is twisted.
The tip of the propeller has a higher angular velocity than the hub of the propeller.
Therefore, the blade must have a lower angle of attack at the blade than at the tip (ie twist)
to produce an even amount of thrust on the blade.
SCHOOL OF ENGINEERING
7
CHAPTER 3
3 DESIGN AND CAD MODEL
Software: Solidworks and OnShape
Propeller Design
Standard Propeller Propeller 2 (higher angle of attack)
Fig. 3.0 on the left shows standard propeller and on the right the re-design higher angle of attack propeller
CAD Model
3.0 Surface modelling
Standard Propeller
Propeller 2
SCHOOL OF ENGINEERING
8
CHAPTER 3
3 DESIGN AND CAD MODEL
3.0 Surface modelling
Surface modelling is first used for engineering simulation to reduce computing load and
also there are lesser surfaces to select for boundary conditions to speed things up.
Propeller 2
Propeller 2 (dimples)
SCHOOL OF ENGINEERING
9
CHAPTER 3
3 DESIGN AND CAD MODEL
Propeller 2 (Bumps)
Propeller 2 (Humps)
Quad_peller
SCHOOL OF ENGINEERING
10
CHAPTER 4
4. MESH & SIMULATION SETUP
Software: Simscale and Solidworks
4.0 Create project in Simscale
4.1 Upload CAD (step file)
4.2 Create Mesh (refer Appendix 1), fine mesh near drone due to turbulence; coarse mesh
at the walls due to very little interaction with air. Type of mesh: Hex-dominant parametric
(only CFD)
4.2.0 Base Mesh (coarse) for Box (Represent air volume around the drone)
4.2.1 Surface Mesh refinement for Rotation of air around propeller
4.2.2 Surface Mesh refinement for drone frame
4.2.3 Surface Mesh refinement (finest) for blades as most changes in air flow here.
4.2.4 Region refinement for Cartesian Box adjacent to drone
4.2.5 Layer refinement to resolve turbulence for drone surfaces.
4.2.6 Run and create Mesh!
SCHOOL OF ENGINEERING
11
CHAPTER 4
4. MESH & SIMULATION SETUP
Cut model of simulation domain; quarter of quadcopter is modelled. Symmetry is use to
reduce the size of the model. Advantage is decrease size of computation model. The outer
box represents the air volume around the quadcopter simulated.
Fig 4.2 Cylindrical solid to define rotation of air around the propeller
SCHOOL OF ENGINEERING
12
CHAPTER 4
4. MESH & SIMULATION SETUP
4.3.3 Choose the Pressure Solver ‘GAMG’ and Velocity Solver ‘Smooth Solver’, K
and Omega.
4.3.4 Choose time step in iterative Simulation Control
Goal in simulation to see which design creating more lift, so in Result Control choose
‘Force and Moment’ and select all faces of the drone.
Create Simulation run for 525 rad/sec, 1050 rad/sec, 1575 rad/sec, 2100 rad/sec. Hit Start!
SCHOOL OF ENGINEERING
13
CHAPTER 5
5. SIMULATION RESULTS
7.0
6.0
5.0
525 rad/sec
4.0 1050 rad/sec
1575 rad/sec
3.0
2100 rad/sec
2.0
1.0
0.0
Std Propeller Propeller 2 Propeller 2 Propeller 2 Propeller 2 Propeller 2
(Benchmark) Dimple Bump Hump Quad_peller
Fig 5.0 shows propeller with higher angle of attack and 4 blades has the most optimal airlift at all rotational
speed
SCHOOL OF ENGINEERING
14
CHAPTER 5
5. SIMULATION RESULTS
Lateral force, Fx(N) vs Propeller type (rad/sec)
0.00
Std Propeller Propeller 2 Propeller 2 Propeller 2 Propeller 2 Propeller 2
(Benchmark) Dimple Bump Hump Quad_peller
-0.05
-0.25
-0.30
0.35
0.30
0.05
0.00
Std Propeller Propeller 2 Propeller 2 Propeller 2 Propeller 2 Propeller 2
(Benchmark) Dimple Bump Hump Quad_peller
-0.05
SCHOOL OF ENGINEERING
15
CHAPTER 5
5. SIMULATION RESULTS
Fig 5.1 shows propeller with higher angle of attack and 4 blades has the maximum velocity field
5.0.1 Velocity Field shows highest air flow for Quad_peller, thus highest airlift. Refer
Appendix 4.
SCHOOL OF ENGINEERING
16
CHAPTER 6
6. TEST PLAN
Fig 6.0 Study of natural resonance of propeller (mat’l ABS) using Solidworks
SCHOOL OF ENGINEERING
17
CHAPTER 6
6. TEST PLAN
Fig 6.2 Test Fixture to secure above a simple weighing machine for measurement of Propeller trust force
Resonance occurs at 250 Hz (15000 rpm / 1570 rad/sec), thus recommended max motor
test speed not beyond 200 Hz (12000 rpm). Safety factor of 1.25
Click https://drive.google.com/open?id=0B-oWcpQpRgJdSWZIQkFTTHlfS0U
SCHOOL OF ENGINEERING
18
CONCLUSION
UP was chosen to print the parts as ABS material is found strong enough in our simulation
for testing with motor and controller up to 15000 rpm. However due to in adequate
material, some of our parts are SLS printed (Nylon material). The SLS propeller passed the
test run with motor and controller.
Some of the small features notably, the dimples and bumps did not turn out as well as we
wanted them to be. Also, for the SLS printed Quad-drone, the Quadra-peller broke off at
the 2mm Ø axle joint easily.
We learnt that Additive manufacturing is good for quick prototype and together with
engineering simulation software to save design time and cost. However, care has to be
taken for fine features. In our case our prototype is functional as well. We can modify to
improve existing propellers on actual quadcopter / drone and replace the current parts to
achieve a more effective lift force.
With CAD software, engineering simulation software and 3D printers, hobbyist and
professional can toy with and exchange different ideas thus stimulating a more vibrant
online community.
SCHOOL OF ENGINEERING
19
APPENDIX
Appendix 1: Mesh Setup
SCHOOL OF ENGINEERING
20
Project Timeline 10 Aug to 19 Oct 2016
Week Week Week Week Week Week Week Week Week Week
1 2 3 4 5 6 7 8 9 10
3D modelling in
Onshape software
3D modelling of the
prototype in Solidworks
software
Fabrication of model in
U-print
Fabrication of actual
model in FDM & SLS
Final Presentation
Preparation of
parts/reports/CADs
submission
SCHOOL OF ENGINEERING
21
REFERENCES
1. Udemy, Engineering Simulation with SimScale: Drone Aerodynamics
https://www.udemy.com/engineering-simulation-with-simscale-drone-
aerodynamics
SCHOOL OF ENGINEERING
22