Staiano, Gabriele (2016) Hydrodynamic Performance of Additive Manufacturing Marine Propellers. [Tesi di dottorato]


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Item Type: Tesi di dottorato
Lingua: English
Title: Hydrodynamic Performance of Additive Manufacturing Marine Propellers
Date: 31 March 2016
Number of Pages: 107
Institution: Università degli Studi di Napoli Federico II
Department: Ingegneria Industriale
Scuola di dottorato: Ingegneria industriale
Dottorato: Ingegneria aerospaziale, navale e della qualità
Ciclo di dottorato: 28
Coordinatore del Corso di dottorato:
de Luca,
Martorelli, MassimoUNSPECIFIED
Gloria, AntonioUNSPECIFIED
Date: 31 March 2016
Number of Pages: 107
Uncontrolled Keywords: Additive Manufacturing (AM); Atomic Force Microscopy (AFM); Computational Fluid Dynamics (CFD); Differential Scanning Calorimetry (DSC); Direct Metal Laser Sintering (DMLS); Fused Deposition Modelling (FDM); Naval Propellers; Open-source 3D Printers; Reverse Engineering (RE); Thermogravimetric Analysis (TGA).
Settori scientifico-disciplinari del MIUR: Area 09 - Ingegneria industriale e dell'informazione > ING-IND/01 - Architettura navale
Area 09 - Ingegneria industriale e dell'informazione > ING-IND/15 - Disegno e metodi dell'ingegneria industriale
Date Deposited: 11 Apr 2016 09:55
Last Modified: 31 Oct 2016 10:56


In recent years, a new generation of Additive Manufacturing (AM) techniques has rapidly become available to the public, due to the expiration of some AM patents and to open-source movements, which allowed significant cost reductions. The aim of this study was to investigate the possibility to use Additive Manufacturing (AM) techniques in the field of naval propulsion, in particular in the fabrication of propellers in model scale, for experimental test, where the manufacturing process was remained almost unchanged in the last 50 years. The naval contextualization responds to need for naval experimental laboratories (Towing Tank and Cavitation Tunnel) for which the high costs are an important limitation for both basic research and for industrial testing. A further scope of applicability of the study is the realization of specialized design of custom propeller for fast boats (typically small) for which, the high cost of production, in relation to the commercial value of the product, has frequently a limitation. Emphasis was placed to printing process parameters and physical and mechanical characterization of materials used to provide reliable and accurate data as references for developers, designers and researchers. The used procedures, were specialized in relation to the intrinsic requirements of the propellers and of the chemical and physical characteristics of the materials. Most marine propellers are made of metallic material such as bronze or steel. The advantages of replacing metal with a polymeric and composite materials are that the latter is lighter and corrosion-resistant. AM process has the potential to dramatically reduce the time and cost required realizing functional metal parts. In addition, the process can fabricate complex internal features not feasible using existing manufacturing processes and allow to fabricate customized propeller. The case study propeller INSEAN E779a, considered in the literature an adequate benchmark, was taken into account. It was fabricated by Direct Metal Laser Sintering (DMLS) EOS M280 in AlSi10Mg metal powder and by an open-source Fused Deposition Modeling (FDM) 3D printer, Prusa Mendel I3 in Acrylonitrile-Butadiene-Styrene (ABS), and UltraT polymeric material. The study of printing parameters and the accurate physical-chemical and mechanical tests on the thermoplastic materials were taken into account, performing Differential Scanning Calorimetry (DSC) analysis, Thermogravimetric Analysis (TGA) and Flexural Tests, and have allowed to optimize the printing process conditions. The evaluation of the printed propellers was carried out by combining their morphological data with the comparison of their performance in respect to the benchmark. A Reverse Engineering system, Faro Articulated Arm Coordinate Measuring Machines (AACMM) CAM2, was used to get the point clouds of each propeller. Using the iterative closest point algorithm of Geomagic Control software of 3D Systems, the point cloud of each propeller was aligned with the CAD nominal model. In such a way the analysis of the deviations was carried out. Atomic Force Microscopy (AFM) test allowed to assess the morphological features and surface roughness of the printed propellers. Towing tank open water propeller tests were carried out and hydrodynamic performance comparison analysis between printed propellers and benchmark, in terms of torque and drag, was analysed. Also, having carried out the measures to 1 kHz sampling frequency, were evaluated the effects, on the hydrodynamic performance of the propellers, of the residual polar asymmetries due to shrinkage associated to AM process. Computational Fluid Dynamic (CFD) analysis were performed to determine the loads acting on the propeller which were used in the experimental bending test on printed propellers. The results, show differences in respect of the thrust generated and of the torque absorbed by the printed propellers, compared to benchmark, as function of the advance coefficient J, of the morphological characteristics and of the materials used. However, the final analysis showed that the substantial adequacy of the AM propellers realized, for most of the studies carried out in Towing Tank. This is due both to the reduced deviations from the nominal model, that to verified constancy of performance offered by each prototype.

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