Innovative Design and Multi-Parametric Computational Investigations on the Propulsive System of a Pentacopter Unmanned Aerial Vehicle

<div class="section abstract"><div class="htmlview paragraph">This work focuses on the design and multi-parametric analysis of a designed propeller for a Pentacopter unmanned aerial vehicle (UAV). The basic and secondary design inputs, along with performance data like propeller diameter, pitch angle, chord length, and lift coefficient, are established using a standard analytical method. Approximately ten distinct airfoils, specifically NACA 2412, NACA 4109, NACA 4312, NACA 4409, NACA 4415, NACA 5317, NACA 6409, NACA 6412, NACA 23024, and NACA 25012, are evaluated over 13 Reynolds Numbers with the angle of attacks (AOA) of 20, varying from -5 to 15 degrees, for the purpose of detailed propeller design. The lift and drag coefficient values for ten distinct airfoils, utilizing a Reynolds number of 13 and 20 angles of attack, are obtained from the XFOIL software. Three sophisticated airfoils are selected from a pool of ten based on their high Lift-to-Drag (L/D) ratio performance. The selected airfoils with a high L/D ratio are NACA 6409, NACA 4109, and NACA 4312. The shortlisted three airfoil-based propellers are designed using a sophisticated modelling tool, i.e., 3D EXPERIENCE. The fourth modelled propeller is designated as the Hybrid propeller, which integrates three airfoils and three propellers, utilizing just NACA 6409, NACA 4109, and NACA 4312 airfoils, respectively. In ANSYS R2 2023 software, the four propellers are examined using a single moving reference frame approach, which facilitates an efficient simulation for the rotating frame in computational fluid dynamics by establishing appropriate boundary conditions. The analysis is conducted using fluid-structure interaction simulations involving carbon fiber reinforced polymer (CFRP), Boron fiber reinforced polymer (BFRP), Kevlar fiber reinforced polymer (KFRP) and glass fiber reinforced polymer (GFRP) materials. Eight distinct materials are evaluated, including BFRP, HMS-CFRP, AS-CFRP, S-GFRP, E-GFRP, GY-70-CFRP, K-49-UD-FRP, and T-300-CFRP. The Hybrid propeller emerges as the optimal performer, particularly when combined with GY-70-CFRP, in terms of minimized total deformation under high loads. The selected propeller is distinguished by reduced torque, which correlates with diminished power consumption during operation, whereas all other propellers display comparable performance metrics concerning the applications relevant to the Pentacopter UAV.</div></div>