Blade shape optimization of an aircraft propeller using space mapping surrogates

Propeller performance greatly influences the overall efficiency of the turboprop engines. The aim of this study is to perform a propeller blade shape optimization for maximum aerodynamic efficiency with a minimal number of high-fidelity model evaluations. A physics-based surrogate approach exploiting space mapping is employed for the design process. A space mapping algorithm is utilized, for the first time in the field of propeller design, to link two of the most common propeller analysis models: the classical blade-element momentum theory to be the coarse model; and the high-fidelity computational fluid dynamics tool as the fine model. The numerical computational fluid dynamics simulations are performed using the finite-volume discretization of the Reynolds-averaged Navier–Stokes equations on an adaptive unstructured grid. The optimum design is obtained after few iterations with only 56 computationally expensive computational fluid dynamics simulations. Furthermore, an optimization method based on design of experiments and kriging response surface is used to validate the results and compare the computational efficiency of the two techniques. The results show that space mapping is more computationally efficient.