Investigation of 3D Printed Underwater Thruster Propellers Using CFD and Structural Simulations

Abstract

Unmanned Surface Vehicles (USV) and Autonomous or Remotely Operated Underwater vehicles (AUV, ROV) are developing and spreading rapidly in various industries. A common feature of these vehicles is that they are propelled by small plastic (or metal) propellers in most cases. Additive manufacturing can offer an excellent opportunity for rapid prototyping and the development of new models. This paper aims to investigate the fundamental aspects to be considered in the geometric design and manufacturing of small (diameter less than 100 mm) PLA (Polylactic acid) propellers 3D-printed using Fused Filament Fabrication (FFF) technology. In-service deformation of 3D-printed PLA ducted propellers with average geometry was investigated to determine the effect on the thrust and torque on the blades. For this purpose, one-directional FSI (Fluid Solid Interaction) simulations were performed using CFD (Computational Fluid Dynamics) and structural simulations. The propeller CAD geometries were generated using an in-house MATLAB script. The variable parameters of each version are the thickness, skew, and rake of the propeller blades. For the structural simulations, it was considered that the material properties of PLA parts printed with FFF technology depend on the print orientation. The results of the simulations show that except for extreme geometries (e.g., thin blades, skew, or rake more than 10°), the deformation of small PLA ducted propellers is not significant. CFD studies of the deformed geometries have shown that the resulting deformation has no significant effect on the thrust and torque of the propeller and thruster.