Open Access

The aerodynamic performance of propellers strongly depends on their geometry and, consequently, on aeroelastic deformations. Knowledge of the extent of the impact is crucial for overall aircraft performance. An integrated simulation environment for steady aeroelastic propeller simulations is presented. The simulation environment is applied to determine the impact of elastic deformations on the aerodynamic propeller performance. The aerodynamic module includes a blade element momentum approach to calculate aerodynamic loads. The structural module is based on finite beam elements, according to Timoshenko theory, including moderate deflections. Several fixed-pitch propellers with thin-walled cross sections made of both isotropic and non-isotropic materials are investigated. The essential parameters are varied: diameter, disc loading, sweep, material, rotational, and flight velocity. The relative change of thrust between rigid and elastic blades quantifies the impact of propeller elasticity. Swept propellers of large diameters or low disc loadings can decrease the thrust significantly. High flight velocities and low material stiffness amplify this tendency. Performance calculations without consideration of propeller elasticity can lead to decreased efficiency. To avoid cost- and time-intense redesigns, propeller elasticity should be considered for swept planforms and low disc loadings.

Dynamic loads significantly impact the structural design of propeller blades due to fatigue and static strength. Since propellers are elastic structures, deformations and aerodynamic loads are coupled. In the past, propeller manufacturers established procedures to determine unsteady aerodynamic loads and the structural response with analytical steady-state calculations. According to the approach, aeroelastic coupling primarily consists of torsional deformations. They neglect bending deformations, deformation velocities, and inertia terms. This paper validates the assumptions above for a General Aviation propeller and a lift propeller for urban air mobility or large cargo drones. Fully coupled reduced-order simulations determine the dynamic loads in the time domain. A quasi-steady blade element momentum approach transfers loads to one-dimensional finite beam elements. The simulation results are in relatively good agreement with the analytical method for the General Aviation propeller but show increasing errors for the slender lift propeller. The analytical approach is modified to consider the induced velocities. Still, inertia and velocity proportional terms play a significant role for the lift propeller due to increased elasticity. The assumption that only torsional deformations significantly impact the dynamic loads of propellers is not valid. Adequate determination of dynamic loads of such designs requires coupled aeroelastic simulations or advanced analytical procedures.

Lifting propellers are of increasing interest for Advanced Air Mobility. All propellers and rotors are initially twisted beams, showing significant extension–twist coupling and centrifugal twisting. Torsional deformations severely impact aerodynamic performance. This paper presents a novel approach to assess different reasons for torsional deformations. A reduced-order model runs large parameter sweeps with algebraic formulations and numerical solution procedures. Generic beams represent three different propeller types for General Aviation, Commercial Aviation, and Advanced Air Mobility. Simulations include solid and hollow cross-sections made of aluminum, steel, and carbon fiber-reinforced polymer. The investigation shows that centrifugal twisting moments depend on both the elastic and initial twist. The determination of the centrifugal twisting moment solely based on the initial twist suffers from errors exceeding 5% in some cases. The nonlinear parts of the torsional rigidity do not significantly impact the overall torsional rigidity for the investigated propeller types. The extension–twist coupling related to the initial and elastic twist in combination with tension forces significantly impacts the net cross-sectional torsional loads. While the increase in torsional stiffness due to initial twist contributes to the overall stiffness for General and Commercial Aviation propellers, its contribution to the lift propeller’s stiffness is limited. The paper closes with the presentation of approximations for each effect identified as significant. Numerical evaluations are necessary to determine each effect for inhomogeneous cross-sections made of anisotropic material.