The document discusses using computational fluid dynamics (CFD) simulation to optimize propeller and fan design. It describes how CFD allows designers to test multiple iterations efficiently to maximize power output while minimizing inefficiencies. The demonstration case uses SimScale software to simulate airflow over a propeller at different rotational speeds, extracting performance metrics like thrust, torque and efficiency to inform design decisions.

1. PROPELLER & FAN DESIGN
USING CFD OPTIMIZATION
DAVID SHORT & ARNAUD GIRIN

2. DAVID SHORT
Application Engineer
2+ years experience in CFD & FEA application
engineering. Coming from a marine
engineering background, he has knowledge of
both solid mechanics and fluid dynamics.

3. ARNAUD GIRIN
Application Engineer
CFD & FEA engineer with extensive expertise
in a wide range of applications. More than
seven years of experience in industrial rotating
equipment design and manufacturing.

4. 1. Benefits of Using Simulation
2. Introduction to SimScale
3. Propeller Design Using CFD
4. Live Demonstration
5. Results Summary
6. Q & A

8. ACCELERATE YOUR
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11. PROPELLER AND FAN DESIGN: TOPIC OVERVIEW
Blades and shroudings can be optimized to
maximize the power output of a device
whilst minimizing losses due to flow
inefficiencies. CFD provides a great solution
for carrying out fast iterations in order to
converge on an optimum design without the
need for excessive physical prototyping.
When it comes to hydrodynamic
or aerodynamic design of
propellers and fans, “efficiency”
is the name of the game.

12. PROPELLER DESIGN EFFICIENCY
The efficiency of a propeller can be defined as:
Where:
● Thrust in N
● Axial Speed in m/s
● Resistance torque in Nm
● Rotational Speed in rev/s

13. PROPELLER DESIGN EFFICIENCY
How we will be calculating this efficiency:
Where:
● T: Thrust in N
● D: Propeller Diameter in m
● Q: Torque in Nm
● n: Rotational in rev/s
● ⍴: density in m3
/kg
● V: Freestream in m/s
Thrust Coefficient
Power coefficient
Advance coefficient
Torque coefficient

14. DESIGN PARAMETERS
● Number of blades
● Outer diameter
● Pitch- Affecting angle of attack
● Leading edge blade angle
● Trailing edge blade angle
Design parameters can impact the
performance of the propellers or fans. These
include (but aren’t limited to):

15. OUR CASE: PROPELLER AT MULTIPLE RPM
● Simulate the airflow passing
over the blades
● Observe the turbulences
created by the rotating motion
● Quantify the performance
indicators such as the torque,
the axial thrust, and the velocity
of the flow
● Determine loading forces acting
on the blades
Objectives

16. CAD IMPORT
Upload your CAD model
or import it from other cloud
services into SimScale.
SIMULATION SETUP
All steps to define and run
a simulation are done
within SimScale.
DESIGN DECISION
Use the simulation insights
to make better and faster
design decisions.
1 2 3

17. CAD IMPORT
Rotating region solid geometry
(this allows us to create a
rotating zone and specify an
rotational speed input)
Propeller solid
geometry
CAD Preparation
Model made of 2 solid
bodies ready to be
imported into SimScale

18. CAD IMPORT
Rotating Region
Using the MRF method, we can
input an angular velocity for
multiple rpm to the volume
surrounding the rotating blades
Propeller Geometry

19. SIMULATION SETUP

20. THE CAD MODEL AND MESH
Mesh Generation: Hex-dominant and Refinement
● Specific refinement applied to the blades and
the wake region. Boundary mesh layers are
adding to the propeller surfaces.
● 6.4 million cells
External Domain
A background mesh box is created to
simulate an external domain.

21. Analysis Type
● Incompressible analysis
● Steady state
● K-omega SST turbulence model
Boundary conditions
● Velocity Inlet
● Pressure outlet
● Slip walls walls for far field
● Non-slip walls are assigned to surfaces
of the duct and propeller
● MRF Rotating zone 6000 rpm(628
rad/s)
SIMULATION SETUP
Velocity Inlet
Pressure outlet

23. EXTRACT THRUST AND TORQUE
Extract thrust and torque values for each operational condition using the
“forces and moments” result control

24. EFFICIENCY CURVES AT DIFFERENT FREE STREAM VALUES
Efficiency values for various rpm at 4 m/s free stream velocity

25. EFFICIENCY CURVES AT DIFFERENT FREE STREAM VALUES
Efficiency values for various rpm at 6 m/s free stream velocity