[Design and analysis of Carbon Fibre Reinforced Plastic (CFRP) propeller blade]

Chapter 1

INTRODUCTION
Marine propeller is a component which forms the principal part of ships since it gives
the required propulsion. Nuclear submarines use nuclear reactors, steam
turbines and reduction gearing to drive the main propeller shaft, which provides the
forward and reverse thrust in the water (an electric motor drives the same shaft when
docking or in an emergency).

The ship propeller is a key component of the motion mechanism of the ship and its play
the main part in propulsion systems. The efficiency of a propeller takes important roles
in the design process, because its efficiency and stabilities directly related. In most
condition, propellers are designed to absorb as minimal power as possible and to give
maximum efficiency with less cavitations and hull vibration characteristics. The
rotation of propeller will create the thrust force for ship motion. This is the main reason
for the weakness blade structure such as blade surface erode, reduced thickness of the
blade and pitched surfaces. These created the high cavitations flow occurred on the
blade surface and the potential of unbalanced forced developed at the end of propulsion

The hydrodynamic aspects of the design of composite marine propellers have attracted
attention because they are important in predicting the deflection and performance of the
propeller blade. Most marine propellers are made of metal material such as bronze or
steel. The advantages of replacing metal with an CFRP composite are that the blade is
lighter and corrosion-resistant. Another important advantage is that the deformation of
the composite propeller can be controlled to improve its performance.

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Chapter 2

LITERATURE SURVEY
P. DurgaNeeharika, et al, “Design and Analysis of Ship Propeller Using FEA”,[2015]The
present work deals with modeling and analyzing the aluminium propeller blade of an
underwater vehicle for its strength. A propeller is a complex geometry which requires high
end modeling software. The solid model of propeller is developed in CATIA-V5 R20 and a
tetrahedral mesh is generated for this model using HYPER MESH and static analysis is
carried out using ANSYS.[1]

M Vidyasagar et al, “Static and dynamic analysis of composite propeller of ship using
FEA”,[2013]This thesis deals with modeling and analyzing the propeller blade of
underwater vehicle for its strength. A propeller is a complex geometry which requires high
end modeling software. The solid model of propeller is developed using CATIA V5
R17.The dynamic analysis of aluminum and composite propeller which is a combination of
GFRP (Glass Fiber Reinforced Plastics) and CFRP (Carbon Fiber Reinforced Plastics)
materials.[2]

Palle Prasad, Lanka Bosu Babu , “ Design and analysis of propeller blade”,[2017]The
present work carries out the structural analysis of a CFRP (carbon fiber reinforced plastic)
propeller blade which proposed to replace the Aluminum propeller blade.This work
basically deals with the modeling and design analysis of the propeller blade of a torpedo
for its strength. This report consists of brief details about Fiber Reinforced Plastic materials
and the advantages of using composite propeller over the conventional metallic
propeller.[3]

Gondi konda reddy ,B shravanthhi, “Design and Analysis of a Propeller Blade Used for
Marine Engine”,[2019] Proposed Most of the marine propellers are made of metal material
such as bronze or steel. The advantages of replacing metal with CFRP composite materials
are that the latter is lighter and corrosion-resistant. Traditionally marine propellers are
made of manganese-nickel-aluminum-bronze (MAB) or nickel-aluminum-bronze (NAB)
for superior corrosion resistance, high-yield strength, reliability, and affordability.[4]

Jaya Kishore.S et al “FEM Analysis on Submarine Propeller Blade for Improved

Efficiency by using Solid Works and ANSYS-Workbench”,[2015] Proposed the FEM
analysis of the propeller blade of underwater vehicles for its strength. The solid model of

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the propeller is developed using solid works. The materials used are aluminum, composite
propeller which is consisting of GFRP (Glass Fiber Reinforced Plastic) and CFRP (Carbon
Fiber Reinforced Plastic) materials. FEM analysis of both aluminum and composite
propeller are carried out in ansys.[5]

V. Ganesh, K. Pradeep, K. Sreeninivasulu Modelling and Analysis of Propeller lade

for its Strength ,[2014] reported on the two distinguished materials for its strength.
Aluminum and CFRP are considered for model and static analysis. The high end software
for modeling was chosen CATIA and for analyzing ANSYS software was used. The
results are compared with the experimental values. By the results the CFRP gives the best
one.[6]

C. Navya, S. Nageswara et al, “ Modelling and analysis of propeller blade for Marine
engine by FEA approach” ,[2018]Analysed Ships and under water vehicles like
submarines, torpedoes and submersibles etc., uses propeller as propulsion. The blade
geometry and its design is more complex involving many controlling parameters. The
strength analysis of such complex 3D blades with conventional formulas will give less
accurate values.Propeller blade material is converted from aluminum metal to fiber
reinforced composite material for underwater vehicle propeller. Such complex analysis can
be easily solved by FEM techniques.[7]

Hassan Ghassemi ,Morteza Ghassabzadeh et al, “Effect of material on hydro-elastic

behaviour of marine propeller by using BEM-FEM hybrid software”, [2013] Analyzed the
effect of material on the hydro-elastic behavior. The geometry of flexible propeller
changes due to hydrodynamic and inertial forces acting on the propeller. By using prepared
software (called HYDRO-BEM and ELASTIC-FEM) the hydro-elastic features of the
propeller made of various materials are analyzed. First, the load acting on the propeller is
determined by using the BEM and deformed propeller geometry is then obtained by the
FEM. Load on the deformed propeller is determined by the BEM and a new shape is
obtained. The iterative procedure is repeated till the blade deflection and hydrodynamic
characteristics (thrust, torque and efficiency) of the propeller become converged. Three
different materials are examined( MAB,CFRP and GFRP).[8]

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2.1 Summary on Literature Survey

The Propeller blade material is replaced from aluminium metal to fibre reinforced
composite material for underwater vehicles propeller and complete analysis can be easily
solved by FEM techniques that can carried out in ANSYS WORKBENCH the propeller
is a complex geometry which requires high end modeling software which deals with
modeling and design analysis of Propeller blade for its strength and propeller blade is
modelled and designed such that it can withstand static load distribution and finding the
stress and deflection for both aluminium and CFRP material and The solid model of the
propeller is developed using solid work CATIA V5 and blade geometry and design are
more complex involving many controlling parameter.

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Chapter 3
OBJECTIVES
 To perform the modal and static analysis for both Aluminium and CFRP
propeller blade.
 To find the total deformation and stresses of Aluminium and Carbon fiber
reinforced plastic materials for propeller blade.
 To compare the results of Aluminium and Carbon fiber reinforced plastic
materials for propeller blade and choose the best material.

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Chapter 4
METHODOLOGY
ANSYS software is widely used in finite element analysis, but its pre-processing
functionis so complex that takes too much time for complex model.
In our project we are going to use CATIA for modelling and FUSION 360 for
meshing and analysis

Fig4.1 Schematic Representation of Methodology

4.1 MODELLING

4.1.1 Introduction to FEA:

Finite element method can be explained through physical concept and hence it is
most appealing to the engineer. And the method is manageable to systematic
computer program and offers scope for application to a wide range of analysis cases.
The basic concept is that a body or a structural may be divided into small elements
of finite dimensions called finite elements. This process of distributing a continuum
into finite elements is known as discretization. The original body or the structure is
then assumed as an assemblage of these elements connected at a finite number of
joints called nodes or nodal points. Same concept is applied in finite difference
method.

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4.1.2 Modelling Composites:

Composites are somewhat more difficult to model than an isotropic material such as iron
or steel. A special care is to be taken in defining the properties and orientations of the
various layers since each layer may have different orthotropic material properties. In this
section, the following aspects of building a composite model are concentrated:
1. Choosing the appropriate element type
2. Defining the layered configuration
3. Specifying failure criteria

4.2 ANALYSIS /SIMULATION

4.2.1 Simulation of Composites:
During machining of composite laminates there is a continuous contact between the tool
and the workpiece due to which fast tool wear and poor surface finish is obtained. This
leads to high costs and challenges in machining of composite materials. To prevent these
drawbacks an alternative solution that is numerical simulations have been developed.
Finite element method (FEM) and discrete element method (DEM) are the two different
types of numerical simulation methods. Although there has been lots of research on
drilling induced delamination by experimental methods, FEM method applied and
analysed to the same has been limited. provides knowledge on number of researchers,
who worked on different machining operations with the application of finite element
method. In this section, work done by various researchers on orthogonal cutting and
drilling induced delamination by using finite element method and discrete element
method has been briefly introduced.

The different types of FEM modelling approaches include

 macro mechanical approach
 micromechanical approach and
 macro-micro combined approach.

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Chapter 5
RESULTS & DISCUSSIONS
5.1 DESIGN CALCULATIONS
5.1.1 For aluminium propeller blade
 Frequency f =36 Hz
 Weight W = 2.12 kg
 Speed N = 36.5×60 = 2190 rpm
 Thrust T = P/V = 29000/7.25=4000 N-m
 Actual Thrust = 0.85 × T = 0.85 × 4000= 3400 N-m
 Actual Thrust per blade =3400/3 = 1133.3 N-m
 Torque Q = 29000 × 60 / (2×π×2190) = 126 51 N-m
 Angular speed ω = 2πN/60 = 229.22 rad/s
 Centrifugal force=m*s1*s1*r=2.12* 229.22* 229.22*0.015=1670.82N

5.1.2 For carbon fiber reinforced plastic propeller blade

 Frequency(F)=87.75 Hz
 Weight W=1.2Kg
 Speed=F*60=87.75*60=5265 RPM
 Thrust(T)=P/V=29000/7.25=4000Nm
 Actual thrust=0.85*T=0.85*4000=3400Nm
 Actual thrust per blade=3400/3=1133.3Nm
 Torque(Q)=p*60/2*3.14*N=29000*60/2*3.14*5265=52.59 Nm
 Angular speed(s1)=2*3.14*N/60=2*3.14*5265/60=551.34 rad/sec
 Centrifugal force=m*s1*s1*r=1.2*551.34*551.34*.015=5471.56 N

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5.2 MODELING OF PROPELLER BLADE BY USING CATIA

 CATIA is much faster and more accurate. Once a design is completed,2D and 3D
views are readily obtainable. The ability to change in late design process is
possible. It is user friendly both solid and surface modeling can be done.

 CATIA provides a greater flexibility for change. For example,if we like to change
the dimensions of our model, all the related dimensions in design assembly,
manufacturing etc. will automatically change. It provides clear 3D models, which
are easy to visualize and understand.

 CATIA provides easy assembly of the individual parts or models created it also
decreases the time required for the assembly to a large extent.

Fig 5.2.1 Modelling of Propeller Blade

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Fig5.2.2 Top View of Propeller Blade

Fig.5.2.3 Left Side View Of Propeller Blade

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5.3 ANALYSIS OF THE PROPELLER BLADE USING ANSYS

Fig.5.3.1 Modal analysis

Fig.5.3.2 Static analysis

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5.4 Modal analysis

A Modal analysis determines the vibration charactactrartics (natural frequencies and
corresponding mode shapes) of a structure or a machine component. It can serve as a
starting point for other types of analysis by detecting unconstrained bodies in contact
analysis or by indicating the necessary time step size for a transient analysis, for example.
In addition the modal analyses results may be used in a downstream dynamic simulation
employing mode. Super position methods, such as harmonic response analysis random
vibration analysis or a spectrum analysis. The natural frequencies and mode shapes are
important parameters in the design of a structure for a dynamic loading condition.
 Carbon fiber reinforced plastic propeller blade

Fig 5.4.1 Total deformation of Carbon fiber reinforced plastic propeller blade

S.NO MODE FREQUENCY

1 1 0
2 2 130.55
3 3 140.69
4 4 174.79
5 5 554.82
6 6 597.31

Table No. 5.4.1 Frequency table for Carbon fiber reinforced plastic propeller blade

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 Aluminium propeller blade

Fig 5.4.2 Total deformation of aluminium propeller blade

S.NO MODE FREQUENCY

1 1 0
2 2 275.8
3 3 297.22
4 4 369.18
5 5 1173.6
6 6 1263.9

Table No. 5.4.2 Frequency table for aluminium propeller blade

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5.5 Static analysis

A Static structural analysis determines the stress, displacements, strains, forces in structures or
components caused by loads that do not induced significant inertia and damping effects. Steady
loading and response conditions are assumed; that is, the loads and the structure’s response are
assumed to vary slowly with respect to time.

 Aluminium propeller blade

Fig 5.5.1 Equivalent stress of aluminium propeller blade

 Carbon fiber reinforced plastic propeller blade

Fig 5.5.2 Equivalent stress of Carbon fiber reinforced plastic propeller blade

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5.6 Results comparison of aluminium and Carbon fiber reinforced plastic

propeller blade

ALUMINIUM CARBON FIBRE REINFORCED PLASTIC

PROPELLER BLADE(CFRP)

WEIGHT 2.12 Kg 1.2 Kg

TOTAL 1.8m 1.3606m

DEFORMATION

EQUIVALENT 5.7137e8 Pa 5.437e8 Pa

STRESS

Table No. 5.6.1 Results comparison

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Chapter 6
CONCLUSION
 Total deflection is more in Aluminium Propeller Blade as compared to Carbon
Fiber Reinforced Plastic(CFRP) Propeller Blade.
 Equivalent stress for Aluminium Propeller Blade is more as compared to
Carbon Fiber Reinforced Plastic(CFRP) Propeller Blade.

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REFERENCES
[1]P. DurgaNeeharika1 , P. Suresh Babu “Design and Analysis of Ship Propeller Using
FEA”,[2015].

[2]M.Vidya Sagar, M.Venkaiah And Dr.D.Sunil ”Static And Dynamic swdsAnalysis Of

Composite Propeller Of Ship Using FEA” ISSN: 2278-0181,Vol.2 Issue 7, July – 2013 .

[3]PALLE PRASAD, LANKA BOSU BABU”DESIGN AND ANALYSIS OF THE

PROPELLER LADE”, International Journal of Advances in Mechanical and Civil
Engineering, ISSN: 2394-2827.

[4]Gondi Konda Reddy, B. SravanthhDesign and Analysis of a Propeller Blade Used for
Marine Engine.

[5]Jaya Kishore.S, B. Siddeswara Rao, P Kumar abu” FEM Analysis on Submarine

Propeller Blade for Improved Efficiency by using Solid Works and ANSYS-Workbench”
International Journal of Emerging Engineering Research and Technology ,Volume 3, Issue
11, November 2015, PP 1-8 ,ISSN 2349-4395.

[6]V Ganesh, K Pradeep, K Sreeninivasulu Modelling and Analysis of Propeller lade

for its Strength ,[2014]

[7]C Navya, S Nageswara , G Kuladeep , K Lakshmikala & S Neeraja” Modelling and

analysis of propeller blade for marine engine by fea approach”, International Journal of
Scientific Research and Review Volume 7, Issue 3, 2018 ISSN NO: 2279-543.

[8] Hassan Ghassemi ,Morteza Ghassabzadeh et al, “Effect of material on hydro-elastic

behaviour of marine propeller by using BEM-FEM hybrid software”, [2013]

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