Surrogate model-based optimisation of UAV aerodynamics and radar cross-section with experimental validation

Abstract This study presents a surrogate-model-assisted Quasi-Newton optimisation framework for simultaneously improving the aerodynamic performance and radar stealth characteristics of an unmanned aerial vehicle (UAV). High-fidelity computational fluid dynamics (CFD) and computational electromagnetics (CEM) simulations are integrated through surrogate models generated via a face-centred central composite design within a design of experiments framework. Quadratic polynomial response surface equations are constructed for key aerodynamic and radar cross-section (RCS) metrics, enabling analytical gradient evaluation. A gradient-based quasi-Newton method with Broyden–Fletcher–Goldfarb–Shanno Hessian updates is employed to minimise a scalarised objective function combining normalised maximum lift coefficient, overall RCS and frontal RCS. Constraints are imposed on the lift-to-drag ratio ( upper L divided by upper D greater than or equals 10 $L/D \geq 10$ L / D ≥ 10 ) and static longitudinal stability ( upper C Subscript m Baseline 0 Baseline greater than or equals 0 ${C_{m0}} \geq 0$ C m 0 ≥ 0 ). Analytical derivatives from the response surface equations (RSEs) eliminate the need for direct numerical differentiation of CFD/CEM outputs, reducing computational cost and eliminating simulation noise. An interior-point sequential quadratic programming strategy is used to ensure satisfaction of nonlinear constraints during the optimisation process. The optimised UAV design demonstrates a 12 percent sign $12{\rm{\% }}$ 12 % increase in maximum lift coefficient and a 30 percent sign $30{\rm{\% }}$ 30 % reduction in both overall and frontal RCS compared to the baseline configuration. The results are confirmed through high-fidelity CFD and RCS simulations and are further validated experimentally in an anechoic chamber, with close agreement across all measured frequencies. The proposed methodology provides an efficient and experimentally verified approach for integrated aerodynamic and stealth optimisation in UAV design.