A data-driven reduced-order model for rotor optimization

Abstract. For rotor design applications, such as wind turbine rotors or urban air mobility (UAM) rotorcraft and flying-car design, there is a significant challenge in quickly and accurately modeling rotors operating in complex, turbulent flow fields. One potential path for deriving reasonably accurate but low-cost rotor performance predictions is available through the application of data-driven surrogate modeling. In this study, an initial investigation is undertaken to apply a proper orthogonal decomposition (POD)-based reduced-order model (ROM) for predicting rotor distributed loads. The POD ROM was derived based on computational fluid dynamics (CFD) results and utilized to produce distributed-pressure predictions on rotor blades subjected to topology change due to variations in the twist and taper ratio. Rotor twist, θ, was varied between 0, 10, 20, and 30∘, while the taper ratio, λ, was varied as 1.0, 0.9, 0.8, and 0.7. For a demonstration of the approach, all rotors consisted of a single blade. The POD ROM was validated for three operation cases: a high-pitch or a high-thrust rotor in hover, a low-pitch or a low-thrust rotor in hover, and a rotor in forward flight at a low speed resembling wind turbine operation with wind shear. Results showed that reasonably accurate distributed-load predictions could be achieved and the resulting surrogate model can predict loads at a minimal computational cost. The computational cost for the hovering blade surface pressure prediction was reduced from 12 h on 440 cores required for CFD to a fraction of a second on a single core required for POD. For rotors in forward flight, cost was reduced from 20 h on 440 cores to less than a second on a single core. The POD ROM was used to carry out a design optimization of the rotor such that the figure of merit was maximized for hovering-rotor cases and the lift-to-drag effective ratio was maximized in forward flight.