Showing posts with label
Propeller Materials and Construction.
Show all posts
Showing posts with label
Propeller Materials and Construction.
Show all posts
1. Propeller
Fundamentals
- A propeller converts engine power into
thrust.
- It acts as a rotating wing producing
aerodynamic lift in the forward direction.
- Each propeller blade is an airfoil
section.
- Thrust is produced by the pressure
difference between the blade surfaces.
- The propeller efficiency is the ratio of
thrust power to engine power.
- Maximum efficiency is around 85%.
- Efficiency decreases at very low or very
high airspeeds.
- The propeller provides both thrust and
engine load.
- Propeller blades work under tension,
bending, and torsional stresses.
- Propeller performance depends on blade
shape, pitch, and speed.
2. Types of
Propellers
- Fixed-pitch propellers have a constant
blade angle.
- Ground-adjustable propellers can be
adjusted on the ground only.
- Variable-pitch propellers can change blade
angle in flight.
- Constant-speed propellers automatically
maintain selected RPM.
- Feathering propellers reduce drag by
aligning blades with airflow.
- Reversible propellers allow thrust
direction reversal.
- Controllable-pitch propellers are manually
controlled by the pilot.
- Constant-speed units use governors to
adjust pitch automatically.
- Feathering is used in twin-engine aircraft
to reduce drag after engine failure.
- Reversing is used for braking during
landing roll.
3. Propeller
Geometry
- Blade angle is measured between the chord
line and the plane of rotation.
- Pitch is the theoretical distance the
propeller moves forward in one revolution.
- Geometric pitch is the designed pitch
angle.
- Effective pitch is the actual distance
moved through the air.
- Slip is the difference between geometric
and effective pitch.
- Blade twist maintains a uniform angle of
attack along the blade.
- The root has a higher angle than the tip.
- Blade chord is the width of the blade.
- The hub connects the blades to the
crankshaft or reduction gear.
- The propeller disc area affects thrust
production.
4. Aerodynamic
Forces
- Propeller blades experience lift and drag.
- Centrifugal force acts outward on rotating
blades.
- Thrust bending force acts forward on the
blade.
- Torque bending force acts opposite to
rotation.
- Aerodynamic twisting moment tends to
increase pitch.
- Centrifugal twisting moment tends to
reduce pitch.
- Vibrations can occur due to aerodynamic or
mechanical imbalance.
- As speed increases, the angle of attack
decreases.
- High RPM can cause compressibility effects
near the tip.
- Blade stress increases with rotational
speed.
5. Fixed and
Variable Pitch Operation
- Fixed-pitch propellers are simple and
reliable.
- They are efficient only at one combination
of speed and power.
- Variable-pitch propellers optimize
efficiency across flight conditions.
- Constant-speed propellers use oil pressure
to adjust pitch.
- The governor maintains selected RPM by
changing blade angle.
- When engine load increases, blade angle
decreases automatically.
- When engine load decreases, blade angle
increases.
- The pilot selects desired RPM using the
propeller control lever.
- Oil pressure is supplied from the engine
or a separate pump.
- Spring and counterweights assist in pitch
change operation.
6. Propeller
Control and Governors
- The propeller governor senses engine RPM.
- It adjusts oil pressure to change blade
pitch.
- A flyweight assembly controls the pilot
valve.
- Flyweights move outwards when RPM
increases.
- This movement ports oil to increase pitch
and reduce RPM.
- When RPM decreases, oil pressure decreases
and pitch is reduced.
- The governor maintains equilibrium between
flyweight and speeder spring forces.
- A speeder spring is adjusted by the
cockpit propeller lever.
- Overspeed condition occurs when RPM
exceeds the selected limit.
- Under speed condition occurs when RPM falls
below the set limit.
7. Feathering and
Reverse Operation
- Feathering aligns blades parallel to
airflow.
- It minimizes drag in case of engine
failure.
- Feathering is achieved by increasing blade
pitch to maximum.
- Feathering systems use oil pressure and
spring or counterweights.
- Automatic feathering may be fitted to some
aircraft.
- Unfeathering uses oil pressure to return
blades to normal pitch.
- Reverse pitch changes blade angle beyond
low pitch.
- Reverse thrust helps slow the aircraft on
landing.
- Beta range includes all blade angles
between fine and reverse.
- Reverse operation is common on turboprops.
8. Propeller
Synchronization
- Multi-engine aircraft use synchronization
systems.
- They reduce noise and vibration caused by
RPM differences.
- The master engine speed is sensed
electronically.
- The slave engine propeller speed is
adjusted automatically.
- Synchrophasing adjusts blade positions for
smoother operation.
- Proper synchronization improves passenger
comfort.
- Synchronizing systems prevent propeller
beat frequency.
- Manual synchronization may be done by
monitoring engine sound.
- Electronic systems use sensors and
actuators.
- Correct adjustment prevents asymmetric
thrust.
9. Propeller
Maintenance
- Propeller blades must be inspected for
nicks and cracks.
- Corrosion is common near the hub and
leading edge.
- Blade tracking ensures all tips follow the
same path.
- Blade balance prevents vibration.
- Static balancing checks propeller balance
at rest.
- Dynamic balancing checks balance during
rotation.
- Grease and oil leakage may indicate seal
failure.
- Pitch change mechanism must be clean and
lubricated.
- Over-speeding may damage the propeller
hub.
- Regular overhaul ensures safe and
efficient operation.
10. Propeller
Materials and Construction
- Wooden propellers are used on light
aircraft.
- Wooden blades are laminated for strength.
- Metal propellers are usually made from
aluminum alloy.
- Metal blades are forged and machined.
- Composite propellers use carbon fiber or
fiberglass.
- Composite blades are lightweight and corrosion resistant.
- Metal hubs provide attachment and load
transmission.
- De-icing boots may be installed on the
leading edge.
- Some propellers use electric or fluid
de-icing systems.
- Proper material choice ensures strength,
efficiency, and safety.