Journal of Mechanical Science and Technology 29 (1) (2015) 227~240

www.springerlink.com/content/1738-494x
DOI 10.1007/s12206-014-1229-5

High performance hydraulic design techniques of

mixed-flow pump impeller and diffuser†
Sung Kim1, Kyoung-Yong Lee1, Joon-Hyung Kim1,2, Jin-Hyuk Kim1,*, Uk-Hee Jung1
and Young-Seok Choi1
1
Thermal & Fluid System R&BD Group, Korea Institute of Industrial Technology, 89 Yangdaegiro-gil, Ipjang-myeon, Seobuk-gu, Cheonan-si,
Chungcheongnam-do, 331-822, Korea
2
Department of Mechanical Engineering, Hanyang University, 222 Wangsimri-ro, Seongdong-gu, Seoul, 133-791, Korea

(Manuscript Received July 9, 2014; Revised September 2, 2014; Accepted September 4, 2014)

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Abstract

In this paper, we describe a numerical study about the performance improvement of a mixed-flow pump by optimizing the design of
the impeller and diffuser using a commercial computational fluid dynamics (CFD) code and design-of-experiments (DOE). The design
variables of impeller and diffuser in the vane plane development were defined with a fixed meridional plane. The design variables were
defined by the vane plane development, which indicates the blade-angle distributions and length of the impeller and diffuser. The vane
plane development was controlled using the blade-angle in a fixed meridional plane. The blade shape of the impeller and diffuser were
designed using a traditional method in which the inlet and exit angles are connected smoothly. First, the impeller optimum design was
performed with impeller design variables. The diffuser optimum design was performed with diffuser design variables while the optimally
designed impeller shape was fixed. The importance of the impeller and diffuser design variables was analyzed using 2k factorial designs,
and the design optimization of the impeller and diffuser design variables was determined using the response surface method (RSM). The
objective functions were defined as the total head (Ht) and the total efficiency (ηt) at the design flow rate. The optimally designed model
was verified using numerical analysis, and the numerical analysis results for both the optimum model and the reference model were com-
pared to determine the reasons for the improved pump performance. A pump performance test was carried out for the optimum model,
and its reliability was proved by a comparative analysis of the results of the numerical analysis and an experiment using the optimum
model.
Keywords: Mixed-flow pump; Impeller; Diffuser; Optimum design; Computational fluid dynamics (CFD); Design-of-experiments (DOE)
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higher value-added business, such as desalination or the ex-

1. Introduction
traction of petroleum, in order to give enterprises that use ad-
Mixed-flow pumps have some characteristics of centrifugal vanced technology an absolute advantage [1-3]. Various re-
pumps and some characteristics of axial-flow pumps. Mixed- search results have been reported by different companies and
flow pumps are mainly used in sewage, water circulation, research agencies [4, 5].
farming, and industrial water applications. Compared to axial- The application of computational fluid dynamics (CFD) in
flow pumps, mixed-flow pumps are smaller and can rotate at the performance analysis of fluid machinery is common, and
higher speeds. many studies have shown its usefulness in predicting the per-
Improving the efficiency of mixed-flow pumps is important formance of pumps. Kim et al. [6] studied the application of
because pumps generally consume energy at a rate greater CFX (a CFD program) in researching the optimum design for
than several megawatts. The importance of designing and fluid machinery where design of experiments (DOE) was also
manufacturing more efficient mixed-flow pumps is increasing employed. The overall results show that the reliability of
as the price of oil increases. Due to the overall need for en- commercial CFD codes, such as CFX, is good enough to use
ergy-saving machinery, researchers are studying the flow field such codes in the optimal design of jet fans, which requires
of mixed-flow pumps in order to develop pumps that are more precise performance analysis.
efficient. This is critical, especially for pumps that are used in There are several optimal design techniques, such as genetic
*
Corresponding author. Tel.: +82 41 589 8447, Fax.: +82 41 589 8330 algorithms, the response surface method (RSM) and DOE,
†
E-mail address: jinhyuk@kitech.re.kr and many papers about their application [7]. When it comes to
Recommended by Editor Dongshin Shin
© KSME & Springer 2015
the optimal design of fluid machinery, and particularly mixed-
228 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240

flow pumps, Kim and Kim [8] have reported the application
of CFX and a few other optimal design techniques used at
other research institutions in the optimal design of fluid ma-
chinery.
There is increasing research about optimal design in which
CFD and optimal design techniques are combined in an at-
tempt to improve the performance of fluid machinery. In most
of the research, commercial CFD codes, such as CFX, are
used as fluid analysis codes. This is because numerical analy-
sis methods using CFD tend to provide straightforward, robust
results that are easy for ordinary users to comprehend [9-12].
In this study, we focused on the impeller and diffuser as the
design variables in order to improve the performance of
Fig. 1. Mixed-flow pump 3D geometry.
mixed-flow pumps. An optimal design was carried out using
DOE and CFD. The variables were defined by the vane plane
development. The meridional plane was fixed after being de-
signed using a database (D/B). An analysis of the influence of
the vane plane development design variables on pump per-
formance and optimum design was conducted using the fixed
meridional plane. Because vane plane development describes
impeller and diffuser shapes and the distribution of blade an-
gles in a simple expression, it is possible to control them.
Vane plane development was designed using the traditional (a) Meridional plane
method in which the inlet and outlet angles are connected
smoothly.
The influence of vane plane development design variables
on the performance of mixed-flow pumps was identified using
DOE and CFD, and the changes in performance were system-
atically analyzed. We determined which design variables sig-
nificantly affected the performance of mixed-flow pumps
using 2 k factorial, optimum designs and the RSM.
Optimally designed impeller and diffuser shapes were com-
(b) Front plane
pared with the results of a numerical analysis of the reference
model in order to understand the reason for the improved total
head (Ht) and total efficiency (ηt) of the optimum model.
Pump test models for optimally designed impeller and dif-
fuser shapes were created in order to carry out performance
tests. The reliability of the optimum shape was determined by
comparing the results of an experiment and a numerical analy-
sis of the optimum design.
(c) Vane plane development

2. Mixed-flow pump design method Fig. 2. Traditional impeller design method [14, 15].

Fig. 1 shows impeller and diffuser shapes for a mixed-flow

pump. A mixed-flow pump primarily moves fluid by elevating
pressure with centrifugal force. The rotating blades of the
impeller impart kinetic energy to the fluid as it flows, and the
energy is converted into pressure energy. In order to satisfy
pump design specifications and design a highly efficient
mixed-flow pump, multiple design techniques are required.
For example, the hydrodynamic design technique is essen-
tial in order to improve mixed-flow pump performance. In-
formation about the meridional and front planes is necessary
to describe the impeller and diffuser, principal components of
mixed-flow pumps. These planes are determined using a cy-
lindrical coordinate system. The meridional plane describes
the basic shape of the blade and shows information about R
and Z in the cylindrical coordinate system.
The front plane expresses blade angles and shows informa-
tion about R and θ. The shape of the impeller and diffuser can
be presented in the meridional plane and front plane, as shown
in Figs. 2 and 3 [13-15]. In Figs. 2 and 3, (a) is a meridional
plane showing the blade shape and represents information
about the direction of the axis and radius; (b) is a front plane
representing the radius and rotational direction; and (c) is the
vane plane development of the impeller and diffuser. The vane
 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240
(a) Meridional plane
(b) Front plane
(c) Vane plane development
Fig. 3. Traditional diffuser design method [15].
plane development shows the blade angle distribution. Axis x
of the vane plane development indicates the total length of the
arc at each radius from the front plane. Axis y indicates the
total length of the blade in the meridional plane. Based on
these explanations, the blade angle distributions can be easily
seen in the vane plane development. The blade angle distribu-
tion is usually achieved by seamlessly connecting the inlet
blade angle and the outlet blade angle. The inlet and outlet
angles of the blade are mainly determined based on pump
design theory.
In this paper, the variables of the impeller and diffuser were
defined with a fixed meridional plane, and an optimum design
for a mixed-flow pump was carried out. Vane plane develop-
ment determines the shapes of the impeller and diffuser.
Therefore, it is essential to analyze changes in mixed-flow
pump performance as a result of different design variables and
to determine the importance of each variable and condition for
optimum design.
2.1 Design of meridional plane
The meridional plane describes the shape and size of the
blade and shows information about R and Z in the cylindrical
coordinate system. Because the meridional plane determines
the diameters of the blade at the inlet and outlet and the curves
of the hub and shroud, it is critical in impeller and diffuser
229
Fig. 4. Meridional plane of the impeller and diffuser.
Fig. 5. Vane plane development design variables for impeller [14, 15].
design. The existing meridional plane is designed based on a
simple empirical basis and on arc type whereby the curve
between the inlet and outlet is connected smoothly. Because
the specifications for a centrifugal pump require low flow rate
and high Ht, the impeller meridional plane of the centrifugal
pump is designed in a way that the fluid enters the pump axi-
ally (in the axis direction) and leaves radially.
On the other hand, because the specifications for axial-flow
pumps require high flow rate and low Ht, the impeller merid-
ional plane of the axial-flow pump is designed so the fluid
enters the pump axially and leaves axially. Because the speci-
fications for a mixed-flow pump are between those for cen-
trifugal and axial-flow pumps, the impeller meridional plane
of the mixed-flow pump has intermediate characteristics of
centrifugal pumps and axial-flow pumps. As the type of im-
peller meridional plane is decided according to the pump
specifications, a mixed-flow pump, which is a design object,
was designed using a D/B.
The outlet shape of the impeller and the area distribution of
the diffuser are important when determining the meridional
shape of the diffuser. The meridional shape of the diffuser was
decided by controlling these two factors. Fig. 4 shows the
newly designed impeller and diffuser shape.
2.2 Design variables in a vane plane development
The impeller and diffuser were designed using vane plane
development. Figs. 5 and 6 show the vane plane development
and the angles and length of the blade. In the figure, h means
hub, m means mid-span, and s means shroud.
∑(R_dθ)_(h, m, s) indicates the total length of the arc at
230 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240

Table 1. Design target (real), design specifications of CFD and CFD

results of the reference model.

Design target Design specifica- Reference model

(real) tions of CFD (CFD result)
Q (CMH) 420 420 420
More than
Total head (m) 17.50 16.13
19.50m
Total efficiency To be maxi-
To be maximized 90.85
(%) mized

Fig. 6. Vane plane development design variables for diffuser [15].

each radius from the front plane. ∑dM_(h, m, s) represents the

total values of the blade length in the meridional
plane. %β1_(h, m, s) and %β2_(h, m, s) show the portion of
the blade having the same blade angle at the leading edge and
trailing edge, respectively, and they are presented as a per-
centage of length out of the whole length of the y-axis.
In other words, x-axis and y-axis in vane plane develop-
ment represent the arc length at each radius from the front
plane and the sum of meridional length. Therefore, the angles
of the β1 and β2 can be expressed by the slope of x-axis and
y-axis. The identical linear angle sections for %β1 and %β2
are defined from the percentage of the entire meridional length (a) Impeller
(∑dM). In particular, when the %β1 is 20%, it can be repre-
sented as the 20% distribution of β1 on meridional length
starting from the leading edge.
β1_(h, m, s) represents the inlet angle of the blade from the
impeller and diffuser, while β2_(h, m, s) represents the outlet
angle of the blade from the impeller and diffuser. R2_dθ_(h, s)
is the degree of inclination toward the circumference from the
hub and shroud at the outlet of the impeller and diffuser. The
inlet and outlet sections are connected by a smooth curved line
whose angle changes linearly [14, 15].
The second part consisting of the paper body must be edited
in double column format. Figures and tables should be located
at top or bottom of either column.
Clear original figures in black and white should be used.
Equations should be numbered consecutively throughout the (b) Diffuser
paper and located at the right margin as in Eq. (1) below. Fig- Fig. 7. Results of grid dependency test.
ures and tables should be placed at the top or at the bottom of
each column as in Fig. 1 and Table 1.
ied from 510,000 to 600,000, while their values for the dif-
fuser did not change as the grid size was varied from 420,000
3. Numerical analysis method
to 520,000. Thus, about 510,000 and 420,000 grid points were
The three-dimensional shape of the impeller and diffuser used to define the mixed-flow pump impeller and diffuser,
was generated using the ANSYS CFX-BladeGen program. respectively, and consequentially 930,000 grid points were
The structured grid system was generated using ANSYS used to define the whole computational domain.
CFX-TurboGrid, a fluid machinery grid generation program. In this study, the boundary conditions for numerical analy-
Fig. 7 shows the results of grid dependency test for the both sis are described in as follows. The impeller has five blades
pump impeller and diffuser. Here, the mixed-flow pump mod- and the diffuser has fourteen blades. Using periodic conditions,
el used for the grid dependency test was used as the reference flow passages with one impeller blade and one diffuser were
model. As shown in Fig. 7, the head and efficiency values for combined for the numerical analysis of the mixed-flow pump.
the reference impeller did not change as the grid size was var- To analyze the linked interface of the impeller and diffuser,
 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240
(a) Impeller
(b) Diffuser
Fig. 8. Boundary conditions and grid system for numerical analysis.
stage-average interface conditions were used [16, 17]. When
the numerical analysis was performed for the impeller only,
the inlet part of the impeller was simplified as a straight pipe.
Figs. 8(a) and (b) show the boundary conditions and grid sys-
tem for the impeller only and the mixed-flow pump (impeller
and diffuser) calculation. We set the atmospheric pressure on
the inlet section of the impeller and the mass flow rate on the
exit section as boundary conditions. The rotational speed of
the impeller was 1780 rpm.
ANSYS CFX-14.5, a commercial CFD code, was used for
the numerical analysis. A three-dimensional Reynolds average
Navier–Stokes equation was used to analyze incompressible
turbulence flow inside the pump. The governing equation was
discretized using a finite volume method. A high-resolution
scheme that has more than a second degree of accuracy, was
used to solve the convection–diffusion equations. For the tur-
bulent model, the shear stress transport k-ω model [18-21],
which is appropriate for the prediction of flow separation, was
231
Fig. 9. Optimization flowchart.
used to analyze turbulent flow through the impeller and dif-
fuser. We used water as a working fluid. Disk friction losses,
mechanical losses, leakage losses, and the tip clearance effect
are not included in this calculation. The specific speed (rpm,
m3/min, m) of the pump was 550, the flow rate was 420 CMH,
and the total head was 17.5 m.
4. Design of experiments
DOE is based on a modern analysis of statistics, which aids
in determining the main cause of abnormal fluctuations. In
this study, 2 k factorial designs and the RSM of the DOE were
used as numerical optimization methods to optimize the de-
sign. Minitab14, a commercial program, was used for the
analysis of DOE [22-24]. The optimization flowchart is shown
in Fig. 9. The optimum design of the impeller of the mixed-
flow pump was accomplished first, followed by fixing the
impeller shape and designing the diffuser. In DOE, a response
variable should be defined in order to analyze the performance
according to the design variables.
The actual response variables are defined in the Ht curve
and the efficiency curve of the pump, as shown in Fig. 10. The
design flow rate is considered to be ideal if the flow rate at
maximum efficiency corresponds with the required flow rate.
Ht and ηt are calculated using the following equations:
pt _ out - pt _ in
Ht = (1)
rg
( pt _ out - pt _ in) ´ Q
ht = . (2)
t ´w
We determined Ht and ηt at the required design flow rate in
232 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240

Fig. 10. Total head and total efficiency curves for response variable [14]. Fig. 11. Central composite design with three factors [14].

order to observe the effect of the impeller and diffuser design

variables.

4.1 2k factorial designs

Generally, 2k factorial designs are represented as nk, the

DOE in which the number of factors is k, and the number of
levels is n. Experiments are performed using every possible
combination of factors. The number of performed experiments
should be at least nk, without repetition.
The advantage of the factorial experiment is that we can as-
sume the main effect (the sole effect of the factor) and the
interaction effect (the effect between factors) of all factors. It Fig. 12. Numerical results of total head and total efficiency curves for
is a convenient screening method that can be used to find the reference model.
core factor when there are many factors involved at the begin-
ning of the experiment. Response surface analysis is used to
determine the changes around the optimum numerical value. of regression analysis where the relationship between two
In this study, considering the number of factors involved and or more predictors and one dependent variable is estimated
the possible experiments, expenses, and time, we used frac- curve line. An estimation equation for curvilinear regres-
tional factorial designs in which the number of experiments is sion analysis is as follows
reduced by deleting less meaningful interactions.
Yˆ = b¶0 + bµ1 ´ X 1 + b¶2 ´ X 2 + L + b¶n ´ X k . (3)
4.2 Response surface method

We used the RSM to examine the relationship between
one or more response factors and quantitative experimental
factors or factor groups. The purpose of this analysis was
to determine the optimal conditions of a factor for optimiz-
ing the response factor. By applying a central composite to
the main factor, which greatly influences the response vari-
able, we generated an experimental set and applied the
RSM. The central composite designs with three factors are
shown in Fig. 11.
Response optimization was performed using regression
analysis. Regression analysis is a statistical process for
estimating the relationships among variables Regression
analysis uses a mathematical model based on data to inves-
tigate the relevance among variables. Generally, the esti-
mated model is used to make necessary predictions or sta-
tistical inferences. Curvilinear regression analysis is a type
X indicates the design variables and b̂ is regression coef-
ficient. Ŷ is established by regression analysis.
5. Design optimization of mixed-flow pump
Table 1 shows the real design target and the modified
design specifications for the CFD cases and the CFD re-
sults for the reference model. The specific speed (rpm,
m3/min, m) of the mixed-flow pump is 550, the flow rate
is 420CMH, the total head is 17.5 m, the total efficiency
should be maximized at the design flow rate. According to
the numerical analysis of the reference model, however,
the numerical analyses for the mixed-flow pump do not
satisfy 17.5 m. As a result, a new design model that satis-
fies the specifications is needed. Fig. 12 shows the numeri-
cal results of total head and efficiency for the reference
 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240 233

Main Effects Plot (data means) for ηt

iβ1_h iβ1_s β2_h
97.80

97.65

97.50

97.35

Mean of ηt
97.20
-14.9 -8.9 -10.8 -4.8 30 36
β2_s %β1 %β2
97.80

97.65

97.50

97.35

97.20
24 30 10 30 10 30

(a) Main effects plot (a) Main effects plot

(b) Pareto chart (b) Pareto chart

Fig. 13. Main effects plot and pareto chart for Ht (2k factorial for im- Fig. 14. Main effects plot and pareto chart for ηt (2k factorial for
peller design). impeller design).

model. Especially, the Ht at design flow rate from the re-
ference model is lowly expected as 16.13 m in comparison
with the requirement point (17.50 m) of design specifica-
tion, as shown in Table 1. Generally owing to the simpli-
fied flow domain, without including disk friction losses,
mechanical losses, leakage losses, tip clearance, roughness
and so on, the results of the numerical analysis should be
expected relatively to be higher than the design target.
Therefore, optimum model should be designed to have Ht
higher than 17.5 m which is design specification consider-
ing disk friction losses, mechanical losses, leakage losses,
tip clearance and roughness.
5.1 Impeller design
5.1.1 Effect of impeller design variables
The impeller design variables selected from the 2k facto-
rial design were the ones with significant influence on the
mixed-flow pump performance. iβ1_h, iβ1_s, and %β1
were selected as design variables for the inlet part. β2_h,
β2_s, and %β2, were selected for the outlet part. iβ1_h and
iβ1_s are the incidence angles at the leading edge of the
blade on the hub and shroud, respectively.
The incidence angles are design variables showing the
difference between the flow angle and the inlet angle. The
variation range of the impeller design variables iβ1_h,
iβ1_s, β2_h, and β2_s were set to be ±3° from each base
design value. The range of %β1 and %β2 was given as
±10%.
The influence of the six impeller design variables on Ht
and ηt was analyzed using a main effects plot and a Pareto
chart and is shown in Figs. 13 and 14. Figs. 13(a) and (b)
show the tendency and importance of Ht according to the
change of impeller design variables. According to Fig.
13(a), Ht increases as iβ1_h, iβ1_s, β2_h, β2_s, and % β2
increase or as %β1 decreases. Fig. 13(b) shows that of the
design variables affecting Ht, β2_s, β2_h, and iβ1_s have
the greatest effect (in the order stated).
Figs. 14(a) and (b) show the tendency and importance of
efficiency according to the change of impeller design vari-
ables. In Fig. 14(a), ηt increases as iβ1_h, iβ1_s, β2_h,
β2_s, and %β2 increase or as %β1 decreases. The tendency
of ηt according to the change of impeller design variables
is the same as that of Ht. However, Fig. 14(b) shows that of
the design variables affecting efficiency, iβ1_s, β1_h,
and %β1 have the greatest effect (in the order stated). To
234 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240
Fig. 15. Main effects plot for Ht (RSM for impeller design).
Fig. 16. Main effects plot for ηt (RSM for impeller design).
summarize the results of the 2k fac torial design, Ht is sig-
nificantly affected by impeller out- let design variables,
while ηt is significantly affected by impeller inlet design
variables. Impeller inlet design is of great importance in
improving the ηt of mixed-flow pumps.
5.1.2 Optimal impeller design
The design variables iβ1_h, iβ1_s, and %β1 were se-
lected as the main variables for RSM using a screening
procedure and the 2k factorial. Fifteen numerical analysis
experiment conditions were created using the central com-
posite method and these three variables. The other design
variables were fixed, considering the results of the 2k facto-
rial design.
Figs. 15 and 16 show the tendencies of Ht and ηt, de-
pending on the change of impeller design variables. In Fig.
15, Ht increases as impeller design variables iβ1_h and
iβ1_s increase or as %β1 decreases. In Fig. 16, iβ1 has the
highest ηt at 4.8°, and the ηt has a tendency to increase
when iβ1_h decreases or when %β1 increases.
In the RSM, considering the loss of the diffuser, the
model with the highest efficiency was selected to be the
target of the design in the impeller design flow rate. The
RSM was used to specify the model-satisfying target value,
Table 2. Comparison of optimization results for impeller design.
Ht (m) ηt (%)
RSM estimated value 20.30 98.04
Optimum model
20.28 97.82
(CFD)
Fig. 17. Response optimization for impeller design.
and the graph of response optimization was drawn as
shown in Fig. 17. As a result of response optimization, the
Ht was predicted to be 20.30 m, and the ηt was predicted to
be 98.04% when iβ_h, iβ_s, and %β1 are -15.7°, -4.0°, and
18.4%, respectively. This result was selected for the opti-
mization design and numerical analysis since it satisfies the
design target value. The numerical analysis result was
compared to the RSM estimated value; these are presented
in Table 2.
5.2 Diffuser design
5.2.1 Effect of diffuser design variables
The variables of the vane plane development of the dif-
fuser were chosen using a 2k factorial experiment. They
were defined as follows; design variables iβ1_h and iβ1_s
were the incidence angles, β2_h and β2_s were the exit
angles, and %β1 and %β2 were the identical blade angles
from the inlet/outlet of the diffuser. The variation ranges of
the diffuser design variables iβ1_h, iβ1_s, β2_h, and β2_s,
were set to be ±3° from each base design value. The ranges
of %β1 and %β2 were given as ±10%. For the influence of
the design variables of the diffuser on the pump perform-
ance, a main effect plot and a Pareto chart were used to
analyze the influence of the six design variables, as shown
in Figs. 18 and 19. Figs. 18(a) and (b) show the tendency
and importance of Ht according to the change of diffuser
design variables. According to Fig. 18(a), Ht increases as
the increment of iβ1_h, β2_s, and % β1. However, iβ1_s,
β2_h, and %β2 need to be decreased for the Ht to increase.
In Fig. 18(b), Ht is affected by variables in the order of
iβ1_s and iβ1_h.
 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240 235

(a) Main effects plot (a) Main effects plot

(b) Pareto chart (b) Pareto chart

Fig. 18. Main effects plot and pareto chart for Ht (2k factorial for dif- Fig. 19. Main effects plot and pareto chart for ηt (2k factorial for dif-
fuser design). fuser design).

Figs. 19(a) and (b) show the tendency and importance of

ηt according to the change of diffuser design variables. In
Fig. 19(a), ηt increases as iβ1_h, β2_s, and %β1 increase or
as ibeta1_s, β2_h, and %β2 decrease. The tendency of ηt
according to the change of diffuser design variables is the
same as that of Ht. Fig. 19(b) shows that of the design
variables affecting ηt, iβ1_s has the greatest influence, fol-
lowed by iβ1_h, the same result as for Ht. To summarize
the results of the 2k factorial, iβ1_s and iβ1_h, which are
inlet design variables, were identified as diffuser design
variables that influence Ht and ηt.

5.2.2 Optimal diffuser design

The diffuser variables iβ1_h, iβ1_s, and %β1, which
have a substantial effect on the Ht and ηt, were screened
using the above 2k factorial. These three design variables
generated 15 experimental conditions of numerical analysis,
including a central value using a central composite method.
The other design variables were fixed, considering the re-
sults of the 2k factorial design.
Figs. 20 and 21 show the effect of the diffuser variables
on Ht and ηt schematically. The tendency of Ht according
to the change of diffuser design variables is shown in Fig.
Fig. 20. Main effects plot for Ht (RSM for diffuser design).
20, while the tendency of ηt according to the change of
diffuser design variables is shown in Fig. 21. In Fig. 20, Ht
is high when iβ1_h is about -2.5° and iβ1_s is -4.5°. Ht is
also high when %β1 is about 30%. In Fig. 21, the tendency
of ηt according to the change of design variables is the
same as for Ht.
In the diffuser design, the impeller has the same ten-
dency because the same optimally designed impeller
236 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240
Table 3. Comparison of optimization results for diffuser design.
Ht (m) ηt (%)
RSM estimated value - 93.52
Optimum model
19.88 93.52
(CFD)
Fig. 21. Main effects plot for ηt (RSM for diffuser design).
Fig. 22. Response optimization for diffuser.
model from the previous study was used. Thus, the loss of
pressure should be minimized in the diffuser design; the
model with the highest efficiency was set as the target of
design.
The response optimization method was used to specify the
shape that satisfies the target value, and the result of the re-
sponse optimization for diffuser is shown in Fig. 22. ηt was
predicted to be 93.52% when iβ1_h, iβ1_s, and %β1 are -2.5°,
-4.5°, and 30.0%, respectively. This result was selected for the
optimization design because it satisfies the design target value.
The numerical analysis result was compared to the RSM esti-
mated value; these are presented in Table 3.
6. Analysis of numerical analysis and experiment results
Fig. 23 shows the three-dimensional geometry for the
mixed-flow pump of the reference and optimum models.
The selected optimum model was verified by numerical
analysis. Table 4 shows a comparison of numerical analy-
sis results for the reference and optimum models. The same
methods were applied for numerical analysis and post
treatment of the reference and optimum models. In Table 4,
(a) Reference model
(b) Optimum model
Fig. 23. Comparison of Three-dimensional geometry for mixed-flow pump.
a 3.73 m improvement in Ht and 2.67% higher ηt are pre-
dicted for the optimum model compared to the reference
model.
Figs. 24(a) and (b) show Ht and ηt curves of reference
and optimum models. The tendencies of Ht curves from
the reference and optimization models are almost same.
Considerable improvements in the Ht curve through opti-
mization were observed in the overall range. On the other
hand, ηt curve for the optimum model also shows the re-
markable improvements, and especially for non-
dimensional flow rate lower than about 1.1, in comparison
with the reference model. Consequently the optimum de-
sign has the highest efficiency value at the de sign point
than that of the design target.
Fig. 25 presents the pressure contour on the meridional
plane of the impeller part in the reference and optimum mod-
els. The overall degree of pressure rise for the optimum model
was higher than the reference model because optimization
process was conducted considering the degree of pressure of
the specifications. In addition, in the case of the reference
model, the degree of pressure rise was different in the shroud
 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240 237

(a) Total head curve

(a) Reference model

(b) Total efficiency curve

(b) Optimum model
Fig. 24. Comparison of numerical results for reference and optimum models.
Fig. 26. Comparison of streamline on blade to blade.

and the hub side. This biased pressure rise leads to non-
uniform flow and results in a reduction in the performance. On
the other hand, the optimum model showed a uniform pres-
sure rise in the shroud and the hub side.
In Fig. 26, flow field is described as streamline for the
reference and optimum models. Fig. 26(a) shows the
streamline distribution for the reference model at 90% span
of the diffuser region. The fluid exiting the impeller does
not flow smoothly in the region of the suction surface near
leading edge of the diffuser inlet. In the optimum model,
(a) Reference model however, fluid flows smoothly in whole 90% span of the
diffuser region, as shown in Fig. 26(b). This shows that the
optimum model has the improved efficiency with the sta-
ble flow field compared to the reference model.
Because the optimum design for the mixed-flow pump
was done using numerical analysis, it is necessary to very-
fy the pump design using a pump performance test.
Pump performance tests were conducted for the optimally
designed impeller and diffuser using test models. Fig. 27(a)
shows the test model for the impeller, Fig. 27(b) the dif-
fuser, and Fig. 27(c) the assembled mixed-flow pump.
Fig. 28 shows a comparison of Ht and ηt curves between
(b) Optimum model
the numerical analysis and experiment results for the opti-
Fig. 25. Comparison of the pressure contour on the meridional plane. mum model. As shown in Fig. 28, the Ht and ηt curves
238 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240
(a) Impeller
(b) Diffuser
(c) Mixed-flow pump
Fig. 27. Test model of the performance evaluation for optimum model.
from the results of the numerical analysis and the experi-
ment have the almost similar tendencies.
However, although they are similar for the numerical
analysis and the experiment, the Ht and ηt curves in the
experiment are predicted to be lower than in the numerical
analysis. This is because a number of factors were not con-
sidered in the numerical analysis, including the bell mouth
of the inlet, disk friction losses, mechanical losses, leakage
losses, the tip clearance effect, machine loss, and rough-
ness loss. According to the comparison of the results of the
numerical analysis and the experiment of the optimally
designed mixed-flow pump, eventually the tendencies of
the Ht and ηt curves are similar.
7. Conclusion
The influence of the design variables of the impeller and
(a) Performance evaluation of the total head
(b) Performance evaluation of the total efficiency
Fig. 28. Comparative analysis of the performance evaluation for opti-
mum model (experiment vs. numerical analysis).
diffuser on performance of the mixed-flow pump was stud-
ied. The optimum model could be induced using the design
variables affecting mixed-flow pump performance. Fol-
lowing are the conclusions drawn from this study.
(1) The meridional plane of the impeller and diffuser for
the mixed-flow pump was designed using a D/B, and the
blade shapes of the impeller and diffuser were also de-
signed using vane plane development.
(2) According to the analysis of the effects of impeller
design variables on Ht and ηt using DOE, it was the exit
part design variables that affect Ht and inlet variables that
affect ηt.
(3) The diffuser of the mixed-flow pump was designed
by analyzing the exit shape and fluid flow of the optimally
designed impeller. The influence of diffuser design vari-
ables on ηt was analyzed using DOE, and it was confirmed
that inlet design variables have a greater effect on ηt than
do exit part variables. Diffuser design variables for the inlet
are important when designing a diffuser because they have
a direct influence on the fluid flow of the impeller exit part.
(4) An optimally designed impeller and diffuser were
verified using numerical analysis. Based on the results of
the numerical analysis, the ηt of the optimum model im-
 S. Kim et al. / Journal of Mechanical Science and Technology 29 (1) (2015) 227~240 239

proved by 2.67% compared to the reference model, and the mark problems for many-objective optimization, Grundfos
Ht of optimum model was improved by 3.73m compared Management Technical Report (2010) no. 2010-01.
to the reference model. By using an optimization technique, [6] M. H. ShojaeeFard, F. A. Boyaghchi and M. B. Ehghaghi,
the possibility of producing an optimally designed impeller Experimental study and three-dimensional numerical flow
and diffuser was confirmed. simulation in a centrifugal pump when handling viscous flu-
(5) In comparing the results of the numerical analysis ids, IUST International Journal of Engineering Science, 17
and the experiment with the optimally designed mixed- (3) (2006) 53-60.
flow pump, the Ht and ηt tendencies were similar. The [7] M. H. Shojaee Fard and M. B. Ehghaghi, Experimental and
reliability of the optimally designed pump was proved us- numerical study of centrifugal pump in the performance of
ing a pump performance test. viscous flow, International Journal of Engineering Science,
13 (3) (2002) 35-52.
[8] J. S. Anagnostopoulos, CFD Analysis and design effects in a
Acknowledgment
radial pump impeller, WSEAS TRANSACTIONS ON Fluid
This research was supported by a grant (No. 10044860) Mechanics, 7 (1) (2006) 763-770.
from the Korea Institute of Industrial Technology Evaluation [9] S. Cao, G. Peng, and Z. Yu, Hydrodynamic design of roto-
and Planning (ITEP), which is funded by the Ministry of Sci- dynamic pump impeller for multiphase pumping by com-
ence, ICT and Furture Planning. bined approach of inverse design and CFD analysis, Journal
of Fluids Engineering, 127 (2005) 330-338.
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Sung Kim received his B.S. and M.S.
degrees from the Korea University of
Technology and Education (KOREA
TECH) and Hanyang University, Korea,
in 2006 and 2009, respectively. He is
currently a researcher in the Korea Insti-
tute of Industrial Technology (KITECH).
His research interests are designs of
turbomachinery, numerical analyses, optimization techniques,
and experimental tests.
Kyoung-Yong Lee received his B.S.
and M.S. degrees from the Korea Uni-
versity of Technology and Education
(KOREA TECH), Korea, in 2002 and
2004, respectively. He is currently Ph.D.
student in Fluid Mechanics at KOREA
TECH, Korea. He has been a Senior
Researcher in Thermal & Fluid System
R&BD Group, at KITECH, Korea. His research interests are
designs of turbomachinery, numerical analyses, system loss
analyses, and experimental tests.
Joon-Hyung Kim received his B.S. and
M.S. degrees from the Hanyang Univer-
sity, Korea, in 2005 and 2007, respect-
tively. Currently he is pursuing his
research towards Ph.D. in Fluid Mecha-
nics at the Hanyang University, Korea.
And he is currently a researcher in the
Korea Institute of Industrial Technology
(KITECH). His research interests are computational fluid
dynamics and design optimization of turbomachinery.
Jin-Hyuk Kim received his Ph.D. de-
gree in Thermodynamics and Fluid Me-
chanics at Inha University, Korea, in
Aug. 2013. He was a postdoctoral re-
searcher in Faculty of Engineering at
Kyushu Institute of Technology, Japan,
from Sep. to Nov. 2013. Since Dec.
2013, he has been a Senior Researcher
in Thermal & Fluid System R&BD Group, at Korea Institute
of Industrial Technology (KITECH), Korea. His research
interests are designs of turbomachinery, numerical analyses,
optimization techniques, and experimental tests.
Uk-Hee Jung received his B.S. and
M.S. degrees from the Korea University
of Technology and Education (KOREA
TECH) and Korea University, Korea, in
2004 and 2008, respectively. He is cur-
rently a researcher in the Korea Institute
of Industrial Technology (KITECH).
His research interests are designs of
turbomachinery, numerical analyses, optimization techniques,
and experimental tests.
Young-Seok Choi received his B.S.
degree from the Seoul National Univer-
sity in 1988, and his M.S. and Ph.D.
degrees in mechanical engineering at the
same university in 1990 and 1996, re-
spectively. He is currently a principal
researcher in KITECH. His research
interests are computational fluid dynam-
ics and design optimization of turbomachinery.