Modular Carbon Fiber PropellerKevin Cullen, Thomas Cummings, Rob Edsall, Sam Henry

Undergraduate, Marine Engineering Technology

MethodsDesign

• Create design parameter• Model propeller in Pro-Engineer design software• Import design into ALGOR Finite Element Analysis Software• Preform stress, fatigue, and failure analysis

Manufacturing• Water-jet the propeller hub by Farmer’s Copper• Shape Expanded Polystyrene (EPS) foam for blade core• Wrap blades in carbon fiber and coat with epoxy resin

Industrial ApplicationsThis blade is designed to be used as an alternative to traditional bronze and other metal propellers. The removable blades will allow ships to make quick and easy repairs to the propeller dockside rather than in a dry-dock. It will also allow ships to remove the blades to prevent damage during long lay-up periods.

IntroductionMarine propellers throughout the years have come a long way. They are the basic instrument by which ships and sub-sea equipment operate. Traditionally, they have been made using bronze, aluminum, or other metal alloys. Recent advancements in carbon fiber technology have made their use prevalent in many other industries. Our goal is to implement a carbon fiber composite material as an alternative to traditional metal propellers.

Finite Element Analysis of propeller blade and hub

Blade profile showing the incorporated NACA files

Pro-Engineer design of blade Actual manufactured blade before carbon fiber coating

PurposeThe purpose of our teams design was to incorporate a light weight durable material, like carbon fiber, with a marine propeller. By utilizing a modular blade design, vessels can easily install or replace blades without the need for dry-docking. The characteristics of this light weight material will provide ships with faster speeds and lower fuel consumption rates. Also, this particular materials ductility leads to longer fatigue life cycles . Finally, carbon fiber provides a corrosion resistant finish that eliminates the need for periodic cleaning that plagues traditional metal propellers because it is biologically inert.

Horsepower 776 SHPRPM 330

Gear Ratio 6:1Ship Speed of Advance 10.7 Knots

Prop. Diameter 74 in.Propeller Pitch 70 in.

Propeller efficiency 60%Apparent Slip 0.37Hub Diameter 14 in.

Shaft Diameter 5 in.Blade Volume 804.37 in3

Blade Mass 63.5 lbThrust Produced 14186 lbfTorque Produced 2250.9 lbf*ft

Theoretical Propeller Design Specifications

Conclusion In conclusion, our design of a carbon fiber modular propeller as analternative to traditional metal propeller was successful in variousapplications. A modular carbon fiber propeller, from what we concludedfrom our results and research, is a more effective design than a metalpropeller for these following reasons:• Replaceable Blades• Lighter Weight• Stronger• Corrosion Resistant• Fatigue ResistantWe conducted a small scale test comparing a composite propeller to abronze propeller and found that the composite propeller was moreefficient. The composite propeller was faster and used less energythan the bronze propeller. We concluded that it takes more energy andtime to get the heavier bronze propeller rotating up to full speedthan the composite propeller. We also concluded that it is much morecost effective to repair a carbon fiber modular propeller than atraditional metal propeller.

Pro Engineer design of propeller assembly

Acknowledgements• Farmer’s Copper• Dr. Rudy Martinez• Mr. Vinny Treglia