Design and Comparative Analysis of an UAV Propeller Using Lightweight Metallic Alloys

This study focuses on evaluating aluminum and magnesium alloys as potential alternatives to carbon fibre for UAV propellers, addressing the challenges of high cost and manufacturing complexity associated with carbon fibre. A detailed propeller model was designed using SolidWorks based on essential geometric parameters. The model was then analyzed in ANSYS Workbench through static structural analysis to assess total deformation, von-Mises stress, strain, and factor of safety under realistic operational conditions, including rotational speed and aerodynamic loads. The analysis revealed that aluminum alloy provides good strength and is easier to manufacture, making it a practical choice. On the other hand, magnesium alloy offers advantages in terms of lower weight and higher specific strength, which can improve UAV performance by reducing overall weight. To ensure the reliability of the simulation results, analytical calculations were also performed for validation. By comparing the structural performance and weight efficiency of these materials, the study identifies the most suitable alternative to carbon fibre that balances strength, weight reduction, and cost-effectiveness. This research contributes to developing more affordable and efficient UAV propellers without compromising structural integrity.