A design methodology for quiet and long endurance MAV rotors

Over the last 10 years, the use of micro air vehicles has rapidly covered a broad range of civilian and military applications. While most missions require optimizing the endurance, a growing number of applications also require acoustic covertness. For rotorcraft micro air vehicles, combining endurance and covertness heavily relies on the capability to design new propulsion systems. The present paper aims at describing a complete methodology for designing quiet and efficient micro air vehicle rotors, ranging from preliminary aerodynamic prediction to aeroacoustic optimization to experimental validation. The present approach is suitable for engineering purposes and can be applied to any multirotor micro air vehicle. A fast-response and reliable aerodynamic design method based on the blade-element momentum theory has been used and coupled with an extended acoustic model based on the Ffowcs Williams and Hawkings equation as well as analytical formulations for broadband noise. The aerodynamic and acoustic solvers have been coupled within an optimization tool. Key design parameters include the number of blades, twist and chord distribution along the blade, as well as the choice of an optimal airfoil. An experimental test bench suitable for non-anechoic environment has been developed in order to assess the benefit of the new rotor designs. Optimal rotors can maintain high aerodynamic efficiency and low acoustic signature with noise reductions in the order of 10 dB(A).