I've been using Alibre to model props. The hope is one off props can be made from these to test different ideas. Other solid modeling programs should be similar but with different quirks to get around. I'm not sure that the current low cost 3D printers are good enough to make props yet. High cost machines can print wax patterns directly, but the cost is still too high for ordinary uses. I think finish machining of castings in high strength materials (NC grinding) will be needed to produce accurate test props with thin blades to absorb that high power electric motors and gas engines can produce. We'll see how accurate 3D printed, investment cast props can get. Wax molds could also be machined from the drawings and would be the way to go for production props.
Surface piercing props have several characteristics that need modeled:
1. Helical pitch - no successful racing propellers have straight helical pitch
2. Pitch progression - many props have a gradual increase in pitch from the leading edge to the trailing edge
3. Cup - most successful props have trailing edge cup, a sharp increase in pitch at the trailing edge
4. Rake - the newer propeller designs have the blades raked to direct the thrust cone more to the rear
5. Edge cup - many racers curl the outside edge of the propeller to help contain the water flow
6. Projected blade shape
I model the prop blade as two helices traveling in different directions from the same cross section. In Alibre you need to create two planes, each with the same cross section, at the same place; one for each helix. The cross section controls blade thickness, cross section shape, rake, and edge cup. Progressive pitch is controlled by the variable ratio of the forward helix. Cup is also controlled the same way on the rearward helix. I start the helix with the same pitch both directions then change the ratio. As an example, if the ratio forward is .5, the pitch at the end of the revolved blade will be 1/2 the start pitch. If the ratio to the rear is 3, the end of the cupped section will be 3 times the start pitch. The projected blade shape is determined with a projected outline using the extrude cut command along the shaft axis. You will have issues with the leading edge thickness toward the forward leading edge, but hand finishing and sharpening will be required in any case.
The propeller examples pictured used a triangular cross section for the helix. I would add thickness to the outside edge as well as some curl or even a tip plate. Testing how these variables affect performance under controlled conditions would be very interesting.
Lohring Miller
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