A Machine Learning Framework for the Prediction of Propeller Blade Natural Frequencies

Characterization of propeller blade vibrations is essential to ensure aerodynamic performance, minimize noise emissions, and maintain structural integrity in aerospace and unmanned aerial vehicle applications. Conventional high-fidelity finite-element and fluid–structure simulations yield precise modal predictions but incur prohibitive computational costs, limiting rapid design exploration. This paper introduces a data-driven surrogate modeling framework based on a feedforward neural network to predict natural vibration frequencies of propeller blades with high accuracy and a dramatically reduced runtime. A dataset of 1364 airfoil geometries was parameterized, meshed, and analyzed in ANSYS 2024 R2 across a range of rotational speeds and boundary conditions to generate modal responses. A TensorFlow/Keras model was trained and optimized via randomized search cross-validation over network depth, neuron counts, learning rate, batch size, and optimizer selection. The resulting surrogate achieves R2>0.90 and NRMSE<0.08 for the second and higher-order modes, while reducing prediction time by several orders of magnitude compared to full finite-element workflows. The proposed approach seamlessly integrates with CAD/CAE pipelines and supports rapid, iterative optimization and real-time decision support in propeller design.