Propeller ThrustReplace this with a short 2 to 3 sentence summary that explains what the project was, why it mattered, and what result or takeaway it delivered.
What needed to be solved
Predict the static thrust of a 254 mm airfoil-based propeller at different rotational speeds using CFD, and validate the simulation results against physical load cell measurements from a custom-built test rig.
Project snapshot
Method
Needed to predict static thrust of a 254 mm two-bladed propeller across RPM range and validate CFD predictions against physical load cell measurements from a custom test rig.
Designed the propeller test stand in SolidWorks, including DFM and material selection. Set up a 3D transient CFD simulation in ANSYS Fluent with rotating/static domains, k-ε turbulence model, and unstructured tetrahedral mesh. Manufactured the housing, assisted with Arduino integration, and performed physical assembly using a mechanical press.
Compared CFD thrust predictions (4.39 N at 1400 rpm, 10.1 N at 1500 rpm, 16.9 N at 2000 rpm) against experimental load cell data. Results confirmed the expected T ∝ ω² relationship.
Tool stack
Software and hardware used throughout the design, simulation, and validation workflow.
Propeller geometry in ANSYS Fluent with rotating domain boundary
ANSYS Fluent velocity-magnitude contour showing the accelerated slipstream and high-velocity region around the propeller blade.
Custom propeller thrust test stand CAD assembly used to support design-for-manufacture and experimental setup planning.
ANSYS Fluent Meshing view showing the outer static domain and the embedded rotating domain around the propeller.
Outcome 01
16.9 NCFD-predicted thrust increased monotonically from 4.39 N at 1400 rpm to 16.9 N at 2000 rpm, confirming the expected T ∝ ω² relationship.
Outcome 02
3 RPMsThrust predictions at 1400, 1500, and 2000 rpm were compared against experimental load cell measurements from the custom-built test rig.
Takeaway
01End-to-end engineering capability from CAD design and DFM of a test rig, to transient CFD simulation, to physical manufacturing and experimental validation.