Preliminary design and simulation analysis of test bench with max thrust of 2000 N for electric propulsion ducted fan experimental investigation

Abstract

This article proposes the calculation and preliminary design of a thrust measurement test stand for an electric Propulsion Ducted Fan (eDPF) -a propulsion device currently widely researched in Urban Air Mobility (UAM) and electric Vertical Take-Off and Landing (eVTOL) aircraft. Initially, a 3D model of the thrust test bench is used to study the structural mesh independence according to the maximum von Mises stress and evaluate the mesh quality parameters. Using a commercial structural numerical simulation package, the investigated model is improved by several changes in geometric dimensions such as heights and positions. After comparing the maximum von-Mises stress of the test bench with values like ductile strength and tensile strength, the results indicate that the improved model performs well under a 2000 N thrust condition. After simulation, the improved model yields a maximum von Mises stress of 119.5 MPa, which is lower than the aluminum's yield strength of 259 MPa. Numerical analysis allows us to develop a recommended model ofthe test stand to put into further production and conduct experiments to measure eDPF thrust according to rotation speed. In addition, the problem of reducing vibration caused by the test stand and integrating additional measurement parameters such as torque, acoustic, etc. also be noted in the future.