Integrated Framework for Advanced Composite Rotor Blade Optimization
Research Poster Engineering 2025 Graduate ExhibitionPresentation by Jiwoo Song
Exhibition Number 30
Abstract
Optimizing rotor blade design is critical for enhancing rotorcraft performance by reducing power requirements, minimizing energy consumption, and increasing range and payload capacity. Multi-disciplinary optimization (MDO) has become a widely adopted approach, integrating constraints from structures, aerodynamics, and aeroacoustics to develop efficient and robust designs. Addressing these factors early in the design process helps mitigate costly revisions and ensures optimal performance. A key challenge in rotor blade optimization is the simplification of cross-sectional geometry, particularly in the definition of the cross-sections. This simplification can lead to inaccurate structural strength predictions and manufacturing infeasibility. While refining geometry definitions could improve accuracy, it would significantly increase the number of design variables, complicating the optimization process. Existing studies have rarely addressed structural strength and manufacturability constraints simultaneously. This work builds upon the integrated VABS (iVABS) framework, an inverse design tool developed by Purdue University, to optimize blade structures based on target stiffness and inertia properties. However, achieving both desired structural performance and manufacturability remains challenging. To address this, a new cross-sectional geometry is developed, ensuring compatibility with industry standards and manufacturing processes. A multi-objective structural optimization is conducted to minimize stiffness and inertia mismatches while incorporating manufacturability constraints. This refined approach enhances the accuracy and feasibility of rotor blade designs, contributing to more practical and effective rotorcraft solutions.
Importance
Rotor blades are critical to the performance of helicopters and other rotorcraft, affecting fuel efficiency, flight range, and carrying capacity. Traditional metal blades are being replaced with advanced composite materials, which offer significant advantages in strength and weight reduction. However, designing these composite blades is complex, requiring a balance between performance, durability, and manufacturability. This research improves rotor blade design by developing a new design template that ensures the blades meet performance goals while remaining practical to manufacture. By optimizing the blade structure with advanced engineering techniques, this study contributes to the development of more efficient, lightweight, and cost-effective rotorcraft. These advancements can enhance military, commercial, and emergency response aviation, making flight operations safer and more sustainable.