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In this work, typical design, production, and testing procedures for a small unmanned helicopter are explained and performed. In doing so, preliminary sizing of the helicopter and three main disciplines are conducted: aerodynamic analytical and numerical simulations, power calculations, and structure analysis assessment. First, a thorough survey is implemented to obtain the trends for the maximum take-off weight versus some design constraints such as rotor diameter, motor power, payload, and empty weight. Performance calculation results are obtained to figure out all aspects that correspond to the specified mission. The designed rotor geometry along with the aerodynamic characteristics and flight performance variables is then validated using the blade element theory and numerical simulations. Second, based on the power curves obtained for different flight regimes, an electric brushless motor is selected. The numerical simulations (Computational Fluid Dynamics) analysis is used to enhance the selection which implies that the motor power should be greater than 5.4 kW to overcome the drag forces. The motor power selection corresponds to a maximum rotor pitch angle of 15^∘ and a maximum rotor speed of 1450 RPM. Then, the aerodynamic loads are used as an input for the structural analysis using one-way coupling of fluid–structure interaction (FSI) and consequently designing the internal structure of the blade. Eventually, the internal structure manufactured using carbon fiber-reinforced polymer (CFRP) by applying a combined technique between wet layup and compression molding. The blade is statically tested compared with numerical finite element model results. The fuselage structure along with hub and tail units is manufactured and assembled with the existing on-shelf components to examine the helicopter lift capability with different payloads up to 9 kg. The results show that the detailed design process is significant for manufacturing such blades and the helicopter is capable of lifting off the ground with various payloads depending on the rotor pitch angles (8^∘, 12^∘, and 15^∘) at a constant rotor speed of 1450 RPM.

The aerodynamic characteristics of a propeller near the rigid ground and static water surface have been investigated numerically and experimentally. The aerodynamic performance of the propeller in various elevations from the ground and the static water surface and tilt angle settings at constant propeller rotational speed have been evaluated. The results indicated that ground and water surface can strongly affect the aerodynamic performance of rotating propellers in close distances up to 1.24 times its diameter. A decrease in the distance between the propeller rotation plane and the surface leads to a remarkable increase of the propeller efficiency up to 15%. Similarly, it has been found that the tilt angle has also noticeable effect on the near-surface aerodynamic characteristics of the propeller. At a tilt angle above 25^∘ almost at any distance from the surface, near-surface effects tend to vanish and propeller thrust reaches its value of free flight condition. Drawing a comparison between near-ground thrust values of the propeller and the thrust values over the surface of water at any predetermined distance from surfaces and tilt angle indicated that the rigid ground has notably higher thrust efficiency than the flexible water surface. At a height of 0.3D (D is propeller diameter) from the ground surface, thrust increased by about 15% while the growth of thrust efficiency near the water surface was about 8%. CFD and Experimental results confirm each other.