PROP_DESIGN does not rely upon momentum theory, Theodorsen's theory of propellers, or the Betz condition. PROP_DESIGN has no light loading limitations either. Therefore, PROP_DESIGN can easily
calculate the static condition. PROP_DESIGN utilizes a novel implementation of lifting-line theory (a.k.a. vortex theory). The formulation is purely analytical with a few exceptions. Empirical
data was used to create the airfoil, atmospheric, and stall models. The empirical data, utilized by PROP_DESIGN, is freely available online. Reputable sources were referenced:
You can use your own airfoil and stall models, if desired. You will have to edit and re-compile the Fortran 77 source code, in order to do so, however. Editing the airfoil and stall models is not
too difficult, as the source code is very clean. The portions which define the airfoil and stall models only consist of a few lines of code.
Using your own airfoil and stall models will require wind tunnel testing and/or 2D CFD. You need to know Cl, Cd, and Cm (i.e. lift, drag, and pitching moment coefficients) for angles of attack of 0 to 90 degrees. These coefficients must be calculated for Mach numbers of .1 to 1.3 and a wide range of Reynolds numbers. Traditional airfoil analysis programs are not capable of accurately determining this information.
PROP_DESIGN executes quickly, and requires little computational resources, because it does not attempt to solve the Euler, Navier-Stokes, or Boltzmann equations. Rather, the Biot-Savart law and the Kutta-Joukowski theorem are utilized to iterate upon induced angle of attack and circulation. As of May 21, 2013, PROP_DESIGN includes the affect of wake contraction. The affect is very small but included for completeness.
PROP_DESIGN is based on a code called PROPSY, described in the following publications:
I have made many corrections and improvements to PROPSY. In fact, at this point, PROP_DESIGN is almost an entirely different program. Therefore, one should not expect the results of the two codes to be the same. Rather than publish these changes via a traditional outlet, I decided to publish them online. This was done to make it easy, and free, for people to obtain them.
PROP_DESIGN is used in combination with several other software programs:
PROP_DESIGN does not calculate aircraft propeller noise levels. This is due to the fact that an efficient aircraft propeller is also a quiet aircraft propeller. Since you normally strive for an efficient design, there is no additional effort required to achieve a quiet design. To calculate aircraft propeller noise levels, I recommend the procedure described below (the document is based on empirical data collected by Hamilton Standard and also contains information showing what aircraft propeller characteristics increase aircraft propeller noise levels):
The paper shows that, if you have an efficient design, there is only one variable left that drives noise. This variable is shaft horsepower. Noise is proportional to shaft horsepower. So the higher the shaft horsepower is the more noise the aircraft propeller will make. Again, from an aircraft propeller design point of view, this means that all you need to do is create an efficient design. Shaft horsepower is dictated by the size of the aircraft. The size of the aircraft is dictated by the max. payload. As an example, if you want to fly four people around, that is going to be much quieter than flying four hundred people around. There is nothing you can do about that. This is why it is a waste of time to worry about noise levels. It is more useful to minimize noise by creating an efficient design. PROP_DESIGN_OPT will automatically find the optimum geometry for any operating condition that a solution exists. So PROP_DESIGN makes it very easy to maximize fuel efficiency and minimize noise.
Below are the other limitations of PROP_DESIGN:
Creating a GUI, exporting complete CAD files, and computing in parallel are outside my programming abilities. PROP_DESIGN already runs very fast using only one CPU thread. So there is little reason to spend the time to re-write or modify the code to run in parallel. I do not believe in using counter-rotating propellers. I don't believe counter-rotating propellers can even work as intended. At their best, it is very easy to prove that they decrease propeller efficiency while increasing noise and cost. I do not believe in using stators, unless they are used in axial flow compressors. In the case of ducted fans, it is easy to prove that stators decrease propeller efficiency and increase cost. The modern turbofan example takes a deeper look into counter-rotating propellers and stators. It is easy to compute the performance of nozzles and diffusers by hand, so there was no reason to include them in PROP_DESIGN. The reference information shows how to perform these calculations. It is best to avoid situations with back pressure, pitch, or yaw. Therefore, I did not specifically address them. I was only interested in creating the best performing propellers. Part of that involves avoiding poor operating conditions as much as possible. This is why I do not believe in tiltrotors, helicopters, and quadcopters. They operate in some of the worst operating conditions, most of the time. Using thrust vectoring nozzles is a much better approach. Thrust vectoring nozzles will increase efficiency, thrust to weight ratio, and safety. They will also decrease cost. Although PROP_DESIGN could be modified to handle marine propellers and wind turbines, I have no interest in these devices. There are many other codes dedicated to marine propellers and wind turbines, so there is little value in expanding the focus of PROP_DESIGN.
The geometry PROP_DESIGN outputs is termed the hot shape. The hot shape is the geometry required to provide the desired aerodynamic performance. FEA is needed to find the corresponding cold
shape. Centrifugal force will deform the cold shape into the hot shape, at a user specified shaft angular velocity. The cold shape is the geometry that should be manufactured.
PROP_DESIGN is unproven. It is up to the user to verify his or her design. To do this, I recommend comparing the results you obtain with PROP_DESIGN against test data that you collect. The typical aircraft propeller design process is as follows:
This is an iterative procedure that is usually conducted by a number of qualified engineers. Many of these steps are performed in parallel, in order to save time and money. Many people manufacture the hot shape, this may cause you to miss your performance target. As you can imagine, this process is very complex, time consuming, and expensive. Many people have been killed due to mistakes in this process.