An Integrated Experimental–Numerical Methodology for Full-Scale Aerodynamic Characterization of Propeller-Driven Unmanned Aerial Vehicles

The aerodynamic characterization of propeller-driven UAVs is often constrained by the unfeasibility of testing the complete airframe–propeller assembly in a wind tunnel, since geometric scaling prevents simultaneous similarity of both the airframe and the propeller. To address this limitation, this work presents an integrated experimental–numerical methodology that reconstructs the full-scale free-air aerodynamic behaviour of a tractor-propeller UAV combining wind-tunnel measurements of the scaled airframe (without the propeller) and the full-scale propeller. Computational fluid dynamics (CFD) is not used to predict the full-scale UAV directly; it is used to predict differences between matched configurations, while the absolute aerodynamic level remains anchored to experiments. Dedicated CFD simulations are carried out to isolate three distinct physical contributions: scale effects, wind-tunnel blockage, and propeller installation effects. In the developed methodology, numerical simulations complement the experimental data to obtain corrected full-scale aerodynamic coefficients and propulsive maps together with a longitudinal force-equilibrium model used to determine the longitudinal force-equilibrium operating point. The reconstruction shows that scale and wind-tunnel blockage effects primarily alter the airframe aerodynamic characteristics, with a minor influence on equilibrium incidence, while propeller installation produces a substantial thrust augmentation due to airframe-induced inflow modification. Accounting for these effects leads to an overprediction of the propeller rotational speed by approximately 23% when installation effects are neglected, demonstrating that the installed performance cannot be obtained by a linear superposition of isolated airframe and isolated propeller data.