Biomimetic Design and CFD-Based Optimization of an Underwater ROV: Hydrodynamic Analysis and Manufacturing Constraints

This study presents a comprehensive Computational Fluid Dynamics (CFD) investigation to optimize the hydrodynamic performance of a Remotely Operated Vehicle (ROV) designed for underwater applications. Inspired by the morphology of the ray fish, three design iterations were analyzed—initial, biomimetic, and manufacturable-final—to assess thrust generation, drag force, pressure distribution, and velocity streamlines across various flow regimes. Using ANSYS CFD and the SST k-ω turbulence model, each configuration was tested at velocities ranging from 0.5 m/s to 10 m/s. Results demonstrated a progressive reduction in drag force from 25.85 N in the initial design to 14.13 N in the final model at 1 m/s, alongside a pressure drop from 550 Pa to 400 Pa. The final biomimetic design, divided into modular sections for ease of manufacturing, achieved an optimal balance between performance and constructability. Moreover, the dome shaped front improved high-speed fluid dynamics but was substituted with a flat face due to fabrication challenges. Pressure contour and streamline analysis confirmed enhanced stability and reduced turbulence in the final design. This work highlights the critical role of CFD in the hydrodynamic refinement of ROVs and demonstrates how biomimicry and engineering pragmatism can converge to yield efficient and feasible underwater systems.