Chapter 3 Marine Propeller Design and Simulation in SolidWorks

137 Pages·2014·6.77 MB·English

A Rapid Development Process for Marine
Propellers Through Design, Simulation and
Prototyping
by
© Xueyin Wu
A thesis submitted to the
School of Graduate Studies
in partial fulfilment of the
requirements for the degree of
Master of Engineering
Faculty of Engineering and Applied Science
Memorial University of Newfoundland
October 2010 Submitted
St. John's Newfoundland
Abstract
Flexibility and speed to market are the keys to successful product development. For
marine propellers, these goals are achieved though iteration of design software and
prototyping. In this thesis, an expanded propeller design code, "OpenPVL_SW",
which was developed based on the Open propeller vortex lattice lifting line code
(OpenPVL), was improved to include propeller geometry generation into SolidWork ,
thrust simulation with CosmosFioWorks and strength assessment with CosmosWorks.
The new code OpenPVL_SW is described in this thesis. In the OpenPVL_SW, a
parametric design technique and a single propeller geometry generator are completed
in MAT LAB, and a propeller blade geometry file for SolidWorks is created after
running the design program.
The purpose of this study is to extend the use of the original OpenPVL code not only
for the propeller design, but also to achieve the thrust simulation and strength check
using SolidWorks tool package, CosmosFloWorks and CosmosWorks. A propeller
geometry, which is provided by Oceanic Consulting Corporation, is simulated to
predict propeller thrust using CosmosFloWorks. A case study designed an AUV
propeller and simulated the thrust with CosmosFloWorks to prove that the
OpenPVL_ SW code provides perfect propeller geometry and a reasonable simulation
result of thrust.
11
Acknowledgements
First and foremost, appreciation and thanks are bestowed upon Prof. Andy Fisher for
his guidance, support and advice. From the beginning stages to the submission of this
thesis, he supported and kept me on the path towards completion, and I did learn a lot
from him. I am greatly indebted.
I expresses thanks to Matthew Garvin, manager of design and fab1ication in Oceanic
Consulting Corporation, for providing propeller geometry, experimental results and
guidance.
I would like to extend thanks to Prof. Mahmoud Haddara. I learned a lot from him
about propeller design and testing.
I would like to acknowledge the support of the people in the rapid proto typing lab for
their support during the propeller fabrication using Stratasys Fusion Deposition
Modeling (FDM).
lll
Table of Contents
Abstract ...................................................................................................................................... ii
Acknowledgements ................................................................................................................... iii
Table of Contents ...................................................................................................................... iv
List of Tables ............................................................................................................................ vi
List of Figures .......................................................................................................................... vii
Introduction .......................................................................................................................... 1
2 Literature and Software Review ............................................................................. oo ..... oooo···· 5
• 2.1 Review of Propeller Design Methods .......... 5
00 .............. 00 00 .. 00 00 ...... 00 .. 00 .................. 00 00
• 2.2 Review of Recent Propeller Design Software .......... 10
00 ...... 00 00 00 ...... 00 ............... 00 00 .. 00.
• 2.3 Review of OpenPYL 13
00 ....................................................... 00 ..................................
• 2.3 .1 Parametric Analysis .................................. 13
00 ....................................................
• 2.3 .2 Blade Design .................................................................................................. 19
• 2.3.3 Propeller Geometry Development Through CAD ........................................... 26
• 2.4 Review of Computer-Aided Design (CAD) ........................................................... 28
•2.5 Review of Computational Fluid Dynamics (CFD) and Finite Element
Analysis (FEA) ................................................................................................... 30
• 2.6 Review of Propeller Fabrication ............................................................................ 32
• 2.6.1 Traditional Fabrication Processes ................................................................... 32
• 2.6.2 Rapid Fabrication Processes ............ oo .. 34
0000 ....................................... 0000 .... 00 .... 00
• 2.7 Review of Propeller Testing 38
.00 ...............................................................................
3 Marine Propeller Design and Simulation in SolidWorks ........................... 43
00 ......................
• 3.1 Open_PYL and OpenPYL_SW Codes ................................................................... 44
IV
• 3.2 Using Solidworks for Propeller Blade Geometry ................................................... 47
• 3.2.1 Propeller Foil Sections .............................................................................. 48
• 3.2.2 Propeller Blade Surface Development. ...................................................... 56
• 3.3 Simulations using CosmosFloWorks ..................................................................... 60
• 3.4 Simulations using CosmosWorks .......................................................................... 66
4 Case Study: Simulation of an AUV Propeller. ..................................................................... 76
5 Case Study: Simulation of a Marine Propeller Provided by Oceanic Consulting
Corporation .................................................................................................... 88
6 Propeller Fabrication by Rapid Proto typing ........................................................................ 98
7 Conclusions and Future Work ........................................................................................... 105
• 7.1 Conclusions ....................... :. ................................................................................ I 05
• 7.2 Future Work ....................................................................................................... 106
References .............................................................................................................................. 10 7
Appendix A: The Part ofOpenPVL_SW MATLAB Source Code for Generating
Propeller Geometry in SolidWo rks ..................................................................... 111
Appendix B: SolidWorks Macro for the AUV Propeller Geometry: ........................................ 119
v
List of Tables
Table 1: Required Input Data for Lifting Line Method and Panel Method ................................... 9
Table 2: Advantages and Disadvantages of Each NACA Series ................................................ 22
Table 3: Prototyping Technology Materials .............................................................................. 35
Table 4: Processes of Propeller Design by Open_PVL and OpenPVL_SW ............................... 46
Table 5: The information ofNACA 63A006 and mean line a=0.8 (modified) ........................... 55
Table 6: Simulation Results of the Three Propellers .................................................................. 83
Table 7: StrataSys FDM 2000 Specifications ............................................................................ 99
VI
List of Figures
Figure 1: Flow Chart of Propeller Design by Computer Programs ............................................... 3
Figure 2: Parametric Analysis Matlab Interface ........................................................................ 14
Figure 3: Efficiency Plot. .......................................................................................................... 19
Figure 4: Propeller Design Matlab Interface ............................................................................. 20
Figure 5: Foil Section Geometry ............................................................................................... 23
Figure 6: Graphical Report························································································:·············· 24
Figure 7: 2D Propeller Blade Profile ......................................................................................... 25
Figure 8: 3D Propeller Image .................................................................................................... 25
Figure 9: Propeller in Rhino ..................................................................................................... 27
Figure 10: Propeller Geometry Validation ................................................................................ 28
Figure 11: Flow Chart of Casting Processes .............................................................................. 33
Figure 12: Wind Tunnel Model Constructed by FDM ............................................................... 36
Figure 13: Sketch of a Propeller Testing Set-up ........................................................................ 38
Figure 14: Thruster Mount. ....................................................................................................... 39
Figure 15: Tow-tank Carriage ................................................................................................... 40
Figure 16: Flow Chart of Generating a Propeller Blade ............................................................. 48
Figure 17: Foil Section Points ................................................................................................... 49
Figure 18: A Propeller Foil Section .......................................................................................... 50
Figure 19: Overview of Propeller Foil Sections ........................................................................ 51
Figure 20: Sideview of Propeller Foil Sections ......................................................................... 52
Figure 21: Foil Section using NACA 65A01 0 a=0.8 at the r/R=0.35 ......................................... 54
Figure 22: Foil Section Using NACA 63A006 a=0.8(modified) at the r/R=0.35 ........................ 56
Figure 23: Propeller Foil Sections and the Leading Edge Line .................................................. 57
Vll