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Rehabilitation and Construction of The Smoke System for The Vertical Smoke
Tunnel

Thesis · June 2018

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Ali Jabbar Al-Khafaji Nibras Mahdi

University of Technology, Iraq University of Technology, Iraq
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 Chapter One Introduction

Chapter One

Introduction

1.1 Introduction

The aim of wind tunnel tests is the simulation of the flow around
bodies or their scaled models. In aeronautical applications, the
measurement of aerodynamic loads in a wind tunnel, forces and
momentums, is a very difficult task due to the required accuracy. The wind
tunnel balances, comprised by several hardware and software components,
provides directly the pursued measurements, with high accuracy and
reliability. For these reasons, among others, wind tunnel balances have
become a common tool in testing facilities.
The number of measuring components and the position of the balance
with relation to the model and wind tunnel chamber determine the wind
tunnel balances designs. The most flexible ones, in terms of usability, are
the six components external balances, so these will be referenced for
introducing the calibration process, which is one of the key points to
achieve the required aerodynamic tests results accuracy and reliability.
Because of its influence on the drag measurement accuracy, the coupling
effect between lift and drag measurements is analyzed very deeply as well.
The analysis of the non-stationary effects are finally done taking into
account the wind tunnel balance requirements and constraints, with special
attention on an issue not commonly mentioned, the inertia forces generated
on the balance by the model vibrations, and their influence on the
aerodynamic forces to be measured. Several mentions to signal processing
and acquisition are done, as this is the other key point on the measurements
accuracy.

1.2 Wind Tunnel Types

The Wind Tunnel has two test sections that can be selected according to
the test purpose. Both test sections are equipped with instruments to
efficiently implement wind tunnel tests.

1
 Chapter One Introduction

1.2.1 Open test section

Is used to test mainly the aerodynamic noise generated from
the test model placed on a supporting gear between the nozzle and the
collector. The cross section of the open test section is 3m wide x 2.5m high.

Figure (1.1) An open test section

1.2.2 Closed test section

5m width x 3m height x 20m length, is composed of a windward wind
tunnel (length 6.5m) and a leeward wind tunnel (length 13.5m), both
separately movable, and used to test and improve the characteristics of the
aerodynamic force and drag work on train models and study the flow
around them.

Figure (1.2) A closed test section

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 Chapter One Introduction

1.3 Classification of Wind Tunnels

Wind tunnels may be classified based on any of the following:
(a) Speed, Mach no:- They are classified as of low speed or high speed
wind tunnels .In wind tunnel parlance, high speed wind tunnels are those
operating at speeds where compressibility effects are important. They are
also classified based on the Mach number of operation as subsonic,
transonic, supersonic or hypersonic wind tunnels.
(b) Mode of operation (Pressure storage, in-draft or Pressure vacuum
type.)
(c) Kind of test section Open, Closed or Semi enclose
1.4 Application of Wind Tunnels
The earliest wind tunnel finds its origins at the end of the19𝑡ℎ
century, when attempts were made to develop heavier-than-air flying
machines. The development of the wind tunnel has huge impact on the
development of airplane. Large wind tunnels begin to appear during the
Second World War During the cold war period, wind tunnel testing were
considered to be of strategic importance since, it would led to the
development of supersonic air-crafts and missiles.
Later on, wind tunnel began to appear for the civilian purposes. With
the invention of modern building materials, man-made structure like
buildings and bridges starts to grow taller and longer than ever it was.
Aerodynamic forces on these structures began to appear as the significant
parameter to consider as these structures grows taller and longer. It became
necessary to deduce these aerodynamic forces while designing these
structures. And this was possible only by wind tunnels. They can be
summarized in the following points:
1. Aerodynamic applications.
2. Non-Aero applications in:
 Civil Engineering.
 Automobile Engineering.
 Calibration of instruments.

3
 Chapter One Introduction

Figure (1.3) A car in an open test section Figure (1.4) Vortexes appear in a smoke
wind tunnel

Figure (1.5) Testing a ball aerodynamically Figure (1.6) Streamlines appears

around a cylinder section

1.5 Flow Visualization

Flow visualization is the art of making flow patterns visible.
Most fluids (air, water, etc.) are transparent, thus their flow patterns are
invisible to the naked eye without methods to make them visible.
Historically, such methods included experimental methods. With the
development of computer models and CFD simulating flow processes (e.g.
the distribution of air-conditioned air in a new car), purely computational
methods have been developed.

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 Chapter One Introduction

1.6 Smoke Wind Tunnel

A small vertical smoke tunnel

will be at your disposal. The
tunnel is an open-circuit
design, powered by a small
variable speed electric fan.
The top mounted fan pulls air
from the room through a
turbulence screen into the
lower, which measures 35.6
cm x 17.8 cm. From the
entrance, the tunnel converges
to the test section, which
measures 10.2 cm x 17.8 cm in
cross-section and is 25.4 cm
long.

Downstream from the test

section, the tunnel converges
to a 12.7 cm diameter circle at
the fan. The speed of the flow
in the test section is controlled
Figure (1.7) Smoke wind tunnel
using the dial located at the
bottom right corner of the
facility.
The calibration that relates the flow speed in the test section to the
dial setting is shown in. The uncertainty of this calibration is not known,
but it is probably no better than 10%. The "smoke", which is vaporized
kerosene, is produced using a Preston-Sweeting mist generator. The
resulting vapor is piped via a black rubber hose into a strut located directly
upstream from the test section. A series of equally spaced holes in the
trailing edge of the smoke strut introduce smoke filaments into the flow.

5
 Chapter One Introduction

During operation of the smoke tunnel it may be necessary to give a

sharp squeeze to the black rubber bulb attached to the end of the strut. This
will clear anything that may be blocking the smoke holes.

In addition, the black rubber hose connecting the smoke generator to

the strut should be drained periodically or whenever the vapor flow is poor.
To drain the hose, remove the end connected to the smoke generator, hold
it towards the floor and give it a few shakes. Take precautions not to shake
the kerosene on your pants leg, as this is easy to do.

1.7 Irregularities of Flow in Smoke Wind Tunnel

1) Spatial non-uniformity; Mean velocity not be uniform over a cross

section. This is overcome by transferring excess total head from
regions of high velocity to those of low velocity.
2) Swirl Flow may rotate about an axis resulting in variation of direction
of flow. Flow straightness and honey combs are used to reduce swirl.
3) Low frequency pulsation these are surges of mean velocity. Under their
influence, time taken for steady conditions becomes excessive. It is
difficult to locate the source of such pulsations.
4) Turbulence generates small eddies of varying size and intensity and
results in time variations of velocity. Turbulence may be defined as
irregular fluctuations of velocity superimposed on mean flow

1.7.1 Losses in the wind tunnel circuit

Losses are due to:
1. Inefficiency of drive unit
2. Skin friction, separation etc
3. Loss of kinetic energy at the diffuser exit
4. Shocks in the case of supersonic wind –tunnels

Losses due to skin friction

6
 Chapter One Introduction

Where A’ is the surface area of the solid boundary which is subjected to

frictional force.

Integral is taken over the length of the duct. L is the perimeter, ds is an

element of length in the direction of flow. A is the cross sectional area and
Cf depends on nature of the boundary layer, Reynolds number and on the
surface nature.

- Losses due to resistance in the wind tunnel circuit

Corner vanes, gauzes and screen offer resistance

1.8 Aim of Present Project

Wind tunnels are designed for a specific purpose and speed range and
there is a wide variety of wind tunnel types and model instrumentation. The
model to be tested in the wind tunnel is placed in the test section of the
tunnel. The speed in the test section is determined by the design of the
tunnel. The choice of speed range affects the design of the wind tunnel due
to compressibility effects.

Aerodynamicists use wind tunnels to test models of proposed aircraft.

In the tunnel, the engineer can carefully control the flow conditions which
affect forces on the aircraft. By making careful measurements of the forces
on the model, the engineer can predict the forces on the full-scale aircraft.
And by using special diagnostic techniques, the engineer can better
understand and improve the performance of the aircraft.

The aim of this project is to rehabilitate the damaged device and

reconstruct the device. While an accidental fire happened, the fire totally
damaged the smoke wind tunnel device.

7
Chapter Two The Smoke Wind Tunnel Construction

Chapter Two
The Smoke Wind Tunnel Construction
2.1 Introduction
The smoke tunnel is one of the
means used to show the flow and
observe its pattern directly through
observation and pictures.

2.2 The Smoke Wind Tunnel

Construction
2.2.1 The Air Flow System
This tunnel is made of steel sheets and
is anchored vertically "on a conveyor of
soft steel pipes and generates airflow By
a fan driven by a speed-changing electric
motor installed at the top of the tunnel
where the air enters the tunnel base, which
represents the entrance" (24 cm) height
and (10 cm) of the test section. "The
direction of the shafts has been selected
vertically" from the top to prevent
problems of firing smoke fumes at low.
The front wall of the test section, while
the front wall is transparent and easy to
lift to be able to change the models and
smoke out of the subject comb At the
bottom of the test section. It contains 23
"holes" for the smoke, and the positions Figure (2.1) – Smoke wind
of these holes diverge in equal dimensions tunnel used
(7 mm) The comb can be moved from side
to side to adjust the smoke level in the air
bag.

This has a bright lighting for the clip Test to be able to clearly see
patterns of distance from a distance. A composite frame on the tunnel
holder is mounted on two switches for lighting Test strip and the other to
operate the fan along with the change knob of the airflow (zero, 3 m / s).

8
Chapter Two The Smoke Wind Tunnel Construction

2.2.1 Smoke Generator

Smoke is generated from the evaporation of the kerosene in a portable
evaporator on the front wall of the smoke generator. The back side is a
bottle containing the supply kerosene. This can be filled after the rubber
payment is removed and the kerosene vaporizer is fed.
The tube base reaches the bottom of the glass evaporator, and a fan that
supplies both the evaporator and the low pressure. An electric resistance
element installed in a leg inside the evaporator is used to heat the kerosene
and to operate both the fan and the heater. And the private key is used and
installed on the hood of the smoke generator.
The evaporated kerosene is then removed from the top of the evaporator.
The external receiver, where smoke is then drawn to the tunnel by a link
carried out at the top of the generator's outer casing.

Figure (2.2) Smoke generator

9
Chapter Two The Smoke Wind Tunnel Construction

2.2.3 Attached Forms:

1. Clip wing of series (NACA

2412) contains a flip flop
2. Circular cylindrical section
3. A circular opening with
sharp edges
4. Circular tablet
5. Half a ball
6. Full ball
7. Thin wing to show the Figure (2.3) Some samples of test sections
influence of the parties

2.3 Model Used

Airfoil NACA0012 is used in the present test. This model is made
from mahogany wood, which used for flow visualization in smoke tunnel
with chord length (150mm) and span length (100mm).

11
 Chapter There Smoke Wind Tunnel Rehabilitation

Chapter There
Smoke Wind Tunnel Rehabilitation

3.1 Introduction
The practical part of rehabilitating of a Smokey-wind tunnel took place
once we brought the device from the university after the department
approval.

3.2 Smoke Wind Tunnel Rehabilitation

1- The device was totally damaged due to the accident that happened in the
fluid laboratory, as shown in the picture.

2- The state of the device at the beginning was useless the outer
case was full of dirt and corrosion. The device’s outer case had to
be fully cleaned before painting.

11
 Chapter There Smoke Wind Tunnel Rehabilitation

3- Some parts of the outer case was damaged due to moving it

from a place to another and the damaged caused by the fire itself,
so we had to fix it.

12
Chapter There Smoke Wind Tunnel Rehabilitation

4- After we cleaned the device from dirt and corrosion. It

looked like this, using a high-speed rotating device with a
cleaning head
And by using ethanol, we cleaned it from dirt and corrosion
Before After

13
Chapter There Smoke Wind Tunnel Rehabilitation

14
 Chapter There Smoke Wind Tunnel Rehabilitation

5- After that we painted it yellow, as it was before

6 - The air system (the motor) was totally damaged, so we bought

a new motor with a small differ from the last one, as shown.

The motor specifications are as follow:

1 – (2600) RPM
2 – (50/60) Hz
3 – (220) V
4 – (0.90) A
5 – (75) Watt

15
 Chapter There Smoke Wind Tunnel Rehabilitation

Electrical connections:
7 - We will connect the air and smoke systems with the
lights via a control box.
There will be 3 switches; one for the smoke system and one for
the air system and one for the light and the wires will be
extended using in-built tubes
8 - The air motor will be controlled by fan-switch in order
to change its speed in 4 different RPMs

Fan switch

Fan ON\OFF

Light Switch

Vapor Switch

16
 Chapter There Smoke Wind Tunnel Rehabilitation

9- The motor was without a fan, so we brought a steel fan to use

it in the motor, and after that we connected the motor to the device
using 4 bolts.

10- We reassembled the device side parts which are the place for
the lights (spot lights) and in which it makes the flow more
visible and clear. Using screws it attach it to the main body.

17
 Chapter There Smoke Wind Tunnel Rehabilitation

To enclose the air and make it comes from the tunnel it self, we
made a steel duct which covers the outer diameter of the fan and
surround it

11- Because that the evaporator operates at 110V, we bought a

transformer which reduce the voltage from 220V to 110V and
connected it to the evaporator.

12- Connecting the wires: Using 2D wires, we reconnected the

wires to the main board which contains 3 switches, one for the
fan with its resistance, one for the vapor fan and the evaporator
itself jointly and one for the lights.

18
 Chapter There Smoke Wind Tunnel Rehabilitation

(Left) the evaporator connection

(Right) The main board connection

Evaporator Evaporator Fan Vapor Vessel

Transformer (Increase speed)

19
 Chapter There Smoke Wind Tunnel Rehabilitation

13- The final assembly

21
 Chapter Four Laboratory Experiments

Chapter Four
Laboratory Experiments

4.1 Introduction
The laboratory is designed to
1. Give your hands on experience of the smoke flow visualization technique,
and
2. Provide you with an opportunity to use this technique to study several wind
tunnel flows.
In general, flow visualization is an experimental means of examining the
flow pattern around a body or over its surface. The flow is "visualized" by
introducing dye, smoke or pigment to the flow in the area under investigation.
The primary advantage of such a method is the ability to provide a description
of a flow over a model without complicated data reduction and analysis. Smoke
flow visualization (Barlow et al., 1999) involves the injection of streams of
vapor into the flow. The vapor follows filament lines (lines made up of all the
fluid particles passing through the injection point).
4.2 Flow Visualization Procedure
The following procedures are designed to help you get a feel for the smoke
tunnel, its models and peripheral equipment. It is important that everybody get
a hands on feel of how to use the apparatus and what its capabilities and
problems are. Feel free to play with the apparatus at this stage, but don't forget
to record your impressions in the logbook.
1- Try out the barometer and thermometer and make initial readings. Try
calculating the atmospheric density and viscosity, are the results sensible?
Make estimates of the uncertainty in these primary measurements.
2- Plug the smoke tunnel's main power cord into a nearby outlet. Check the
kerosene liquid level (bottom left of tunnel), and adjust or top up the bottle as
necessary. Be patient - the smoke generator takes as much as 10 minutes (after
the liquid level is adjusted correctly) to start producing satisfactory quantities
of smoke. (If you can't get much smoke, or the smoke dies off after a while try
shaking out the black rubber hose that delivers the smoke to the strut. Turn on

21
 Chapter Four Laboratory Experiments

the fan (bottom right of the facility) and set the dial to a moderate speed (say
40).
3- While the tunnel is warming up set up the digital. Try out the camera. Try
taking photos, and transferring them to your electronic logbook. Photos of the
smoke streams tend to be better when taken with the lights in the immediate
vicinity of the tunnel turned off. Try setting up the camera on the tripod as close
to the test section window as you can.
4- When the smoke starts coming, take off the test section window and insert
a model. Replace the window and look at the flow. Squeeze the bulb if you
need to clear any of the smoke holes. Try a photo - with flash, without, what's
best?
5- Try different models to see what the flow is like. Try varying the speed (i.e.
Reynolds number) and strut position with each model and see what happens.
Do you agree with the uncertainty estimate of 10% for the wind tunnel speed
calibration? If not, how good is it in your opinion? The airfoil is a particularly
interesting model since you can change the angle of attack (line the trailing
edge up with the marks on the back of the test section). As you check out these
flows, make a list in the logbook of important things to do/measure when you
run the real test. E.g.. measure the model (which dimensions?), measure where
it is in the test section
6- Try making a list in the logbook of any problems with the apparatus that
you think might affect the quality of your results. A good way of judging the
flow quality is to look at the smoke flow pattern with no model. Try sliding the
smoke strut back and forth to visualize the whole flow, varying the speed. Do
you see any imperfections? Do the imperfections change with speed? Are they
worth documenting (this may depend on the goals you choose)?
7- Try putting in the modified window to reduce the test section width - what's
the quality of the flow with this? Do you think this will be useful for studying
blockage effects?
B. Designing and implementing the smoke flow visualization experiment
Now that you are familiar with the capabilities and limitations of the
smoke tunnel and smoke flow visualization system, you are ready to exploit
them to achieve a scientific goal. Choose goals from the following list. (You
may also modify these goals or choose a different goal of your own, but that
goal must be scientific, and clearly stated in the logbook).

22
 Chapter Four Laboratory Experiments

Goal 1. Design, conduct and document a sequence of tests to determine the

location of stall on the NACA 2412 airfoil as a function of angle of attack at a
fixed Reynolds number, and to assess wind tunnel effects that may have
influenced your results. Suggestions: Don't forget to look at the lists you
generated above. For wind tunnel effects, you might try documenting the
empty test section flow at the same condition, or using the modified test section
window (to see if a change in blockage has any effect - you may need to try
this at a range of angles of attack).
Goal 2. Design, conduct and document a sequence of tests to take careful
flow visualization pictures of a range of flows you have discussed previously in
AOE 3014 at a fixed Reynolds number, and to assess how wind tunnel effects
may have influenced your results.
Suggestions: Don't forget your lists of things to measure in a real test - careful
documentation of each flow will greatly enhance the value of your results.
Choose a Reynolds number where you get good pictures. See suggestions above
on wind tunnel effects.
Goal 3. Choose a model flow. Design, conduct and document a sequence of
tests to examine the effect of Reynolds number upon that model flow, and assess
the extent to which wind tunnel effects may have influenced your results.

4.3 The results

The outcome of all the previous work and procedure is to notice the
flow behavior around a specific object (Airfoil) at different positions,
identify the flow separation and the flow behavior at the high angle of
attacks..

At 0º AOA:

- No separation is noticed as
the flow is laminar.

23
 Chapter Four Laboratory Experiments

At 3º AOA:-
The separation is at its beginning as the
AOA is increased slightly
As we know, the pressure on the upper
surface (left) will be more than the
lower (right) surface

At 5º AOA:-

The separation will be more noticeable

in the leading edge of the airfoil
section

At 10º AOA:-
The lift coefficient will be increased,
depending on the NACA section. Here
in this section the separation is huge
which will decrease the velocity over the
section, thus, no life will be generated

At 15º AOA:-

Here, the angle is called 𝛼𝑠 (Stalling

angle) for the major types of NACA.
That means that no flow will be
generated in the upper surface
because is the separation in the
boundary layer is huge

24
The Conclusion

The Conclusion
From this research, we conclude: -
1. Building a wind tunnel is not very complicated but expensive.
2. For visualization aspects, such wind tunnel is very suitable especially
for under graduated student.
3. The simplicity in this wind tunnel is what giving it the creativity.
4. We can test more than Airfoil type in the wind tunnel

25
 References

References:
1. Wikipedia, free encyclopedia. Wind tunnel. [Online]
Available from:
https://en.wikipedia.org/wiki/Wind_tunnel#Aeroacoustic_tunnels
2. Wikipedia, free encyclopedia. Vertical wind tunnels. [Online]
Available from: https://en.wikipedia.org/wiki/Vertical_wind_tunnel
3. Wikipedia, free encyclopedia. Flow visualization. [Online]
Available from:
https://en.wikipedia.org/wiki/Flow_visualization
4. Wikipedia, free encyclopedia. Subsonic and transonic wind tunnel.
[Online]. Available from:
https://en.wikipedia.org/wiki/Subsonic_and_transonic_wind_tunne
l#Subsonic_tunnel
5. NASA Glenn Research center. ‘Little smookie’ wind tunnel.
[Online].
6. W.J. Devenport and W. L. Hartwell. Experiment 1 - FLOW
VISUALIZATION. 2009. [Online]
7. Alan Pope & John, J. H., “Low Speed Wind Tunnel”, John Wiley &
Sonc., New York / London. 2001
8. John J. Bertin & Michael L. Smith, “ Aerodynamics for Engineering
” , Prentice Hall. 1979.
9. Aerodynamic Lab. Technical Notes, Mechanical Department,
University of Technology. Iraq
10. I. H. Abbott & A. E. Van Doenhoff , “ Theory of wing Section ” ,
McGraw-Hill ,NY. 1959.
11. Alan Pope, “Basic Wing & Airfoil theory” , McGraw-Hill . 1951.

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