Exploring the potential of toroidal propellers: A comprehensive study on design, optimization, and experimental validation
Aerospace Science and Technology, vol.177, 2026 (SCI-Expanded, Scopus)
- Publication Type: Article / Article
- Volume: 177
- Publication Date: 2026
- Doi Number: 10.1016/j.ast.2026.112738
- Journal Name: Aerospace Science and Technology
- Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Compendex, INSPEC, zbMATH, Academic Search Ultimate (EBSCO), Engineering Source (EBSCO)
- Keywords: Aeroacoustic analysis, Experimental validation, Liutex vortex identification, Low-noise propeller design, Response surface methodology, Toroidal propeller
- Middle East Technical University Affiliated: Yes
Abstract
This study presents a comprehensive framework for the design and optimization of toroidal propellers as a high thrust, low noise signature propeller for drones. A numerical framework is developed in OpenFOAM to select a promising baseline toroidal concept. A design of experiment methodology with response surface models is employed to optimize key geometric parameters, with a sensitivity analysis quantifying their influence on thrust, torque, and noise. The optimized design achieves a 35% increase in thrust and an 11% reduction in overall sound pressure levels compared to a conventional propeller at a given RPM. Aeroacoustic analysis supported the propeller’s suitability for noise-sensitive missions. The final design is fabricated via stereolithography and experimentally tested, with results closely matching numerical calculations.