Design, aerodynamic, and structural integrity investigations of the advanced three bladed propeller for high payload based unmanned aerial vehicles

• This study aimed to develop a propeller with exceptional aerodynamics and structural integrity by analyzing different materials. • Computational Fluid Dynamics was used to assess the propeller design's aerodynamic performance. • The research used fluid-structure interaction analysis to evaluate the impact of aerodynamic forces on the propeller's structural integrity under different operational conditions. • Kevlar 49 and Carbon GY 70 based hybrid composite offers the lowest density and equivalent stress, making it ideal for propeller fabrication. Drones are increasingly used in demanding environments like mines, forests, and urban areas, necessitating enhanced structural integrity technologies. To manage larger payloads efficiently, a specialized drone-propeller has been developed that adjusts its thrust based on requirements. All the analyses in this study were proceeded using ANSYS Workbench23, in which the aerodynamic performance of the propeller is studied by using ANSYS Fluent and the fluid-structure-interaction simulations were executed using ANSYS structural. Evaluating a propeller's structural integrity is essential for performance, safety, and durability. This paper analyzes the structure and performance of a lightweight high-payload propeller made from various materials, focusing on its efficiency at high RPMs. Evaluating its structural integrity is crucial for assuring performance and safety, particularly since the initial design was inadequate at higher speeds. Low and high-load conditions were simulated by incorporating different RPM conditions. Structural results such as Total deformation, Normal stress, Equivalent elastic strain was noted and compared with other materials to find the best one for the specific application. By the end of this research, it was concluded that Kevlar-49-Epoxy and CFRP-GY-70 composite were best in withstanding the loads acting on the propeller and with that knowledge, a hybrid composite material was developed using ANSYS Material Designer for withstanding the high payloads while maintaining lower normal stress. The density of the hybrid material is 82.47% lower than that of CFRP-GY-70 and 49% lower than KFRP-49-composites, making it the most suitable material for fabricating the proposed propeller as it is lighter and durable with good flexibility.