MODELLING AND ANALYSIS OF

CAMSHAFT
A MINI PROJECT REPORT
Submitted in Partial fulfillment of the award of Degree of Bachelor of
Technology in Mechanical Engineering

Submitted by

P.SRINIVAS -19H65A0333
P.NAVEEN -19H65A0335
P.SAI PRANEETH -19H65A0340

Under the guidance of

Mrs.A.Pooja.
Department of Mechanical Engineering

ANURAG GROUP OF INSTITUTIONS [14]

(An Autonomous Institution) [14]
(Approved by AICTE, Accredited by NBA & Affiliated to JNTU, Hyderabad)
Venkatapur(V) Ghatkesar (M) RangaReddy (Dist.), Telangana 500088
December,2021

ANURAG GROUP OF INSTITUTIONS

 (An Autonomous Institution)
Venkatapur(V) Ghatkesar (M) RangaReddy (Dist.), Telangana 500088.

Department of Mechanical Engineering

CERTIFICATE

This is to certify that the work embodies in this dissertation entitled ‘

MODELLING AND FE ANALYSIS OF CAMSHAFT’ being
submitted by ‘P SRINIVAS[19H65A0333],P NAVEEN
[19H65A0335],P SAI PRANEETH[19H65A0340]’ for partial fulfillment of
the requirement for the award of Bachelor of Technology in Mechanical Engineering
to Anurag Group of Institutions, Venkatapur(V) Ghatkesar (M) RangaReddy (Dist.),
Telangana State. During the academic year 2021–22 is a record of bonafide work,
undertaken by him/her the supervision of the undersigned.

Approved and Guided by

Signature Signature

Mrs. A.Pooja. Dr. S. Madhu M.E., Ph.D.

Designation, Department Head of the Department
AGI, Hyderabad Mechanical Engineering

External Examiner
 ANURAG GROUP OF INSTITUTIONS [16]
(An Autonomous Institution) [14]
Venkatapur(V) Ghatkesar (M) RangaReddy (Dist.), Telangana 500088. [14]

Department of Mechanical Engineering [14]

DECLARATION [16]
We ‘Candidate Names’, are students of ‘Bachelor of Technology in Mechanical
Engineering’, pertaining to 2018 – 22 batch, Anurag Group of Institutions, Venkatapur
(V), Ghatkesar (M), RangaReddy (Dist.), Telangana State, hereby declare that the
work presented in this Mini Project Work entitled ‘Topic Name’ is the outcome of our
own bonafide work and is correct to the best of our knowledge and this work has been
undertaken by taking care of Engineering Ethics. It contains no material previously
published or written by another person nor material which has been accepted for the
award of any other degree of the university or other institute of higher learning, except
where due acknowledgment has been made in the text. [14]
P.Srinivas.
[19h65a0333]
P.Naveen
[19H65A0335]
P.Sai Praneeth
[19H65A0340]
 ABSTRACT

Centrifugal pumps are used to transport liquids/fluids by the conversion of the rotational kinetic
energy to the hydro dynamics energy of the liquid flow. The rotational energy typically comes
from an engine or electric motor or turbine. In the typical simple case, the fluid enters the pump
impeller along or near to the rotating axis and is accelerated by the impeller, flowing radially
outward into a diffuser or volute chamber (casing), from where it exits. The Contemporary
impeller blades in Centrifugal pumps are used in industrial applications are made up of
Aluminium or Steel. It is proposed to design a centrifugal pump using Computer Aided Design
(CAD) software with various metal alloys and NonMetallic composite materials, analyze its
strength and deformation using simulation software. In order to evaluate the effectiveness of
Metal Alloys and NonMetallic composites. The present work aim is to change the material and
performing the different analysis like Static, Dynamic, Analysis to find the best material to
decrease the weight and increase its efficiency by using the software SOLID WORKS (2014
Premium Version). This also involves the method of manufacturing process to realize the Blower
using Non-Metallic composite material.

Key Words: Centrifugal pump, Computer Aided Design (CAD), Metal Alloys, Non-Metallic
Composite Materials, SOLIDWORKS, Simulation Analysis.

1
Table of Contents
Chapter 1..........................................................................................................................................4
Introduction......................................................................................................................................4
1.1 CLASSIFICATION...............................................................................................................4
1.2 Centrifugal Pumps..................................................................................................................5
1.3 SELECTION OF A PUMP....................................................................................................8
1.4 CENTRIFUGAL PUMP........................................................................................................8
1.5 Applications of the Centrifugal Pump.................................................................................10
1.6 Composite materials.............................................................................................................11
1.7 PROPERTIES AND APPLICATIONS OF COMPOSITE MATERIALS.........................12
Chapter 2........................................................................................................................................13
Literature Review..........................................................................................................................13
2.1 OBJECTIVES OF THE PROPOSED WORK.....................................................................24
Chapter 3........................................................................................................................................25
Methodology..................................................................................................................................25
3.1 Modelling.............................................................................................................................25
3.2 Materials...............................................................................................................................27
3.3 ANALYSIS OF FLUID FLOW DOMAIN.........................................................................28
3.3.1 Introduction to CFD......................................................................................................28
3.4 Boundary conditions............................................................................................................31
Chapter 4........................................................................................................................................33
Results and discussion...................................................................................................................33
4.1 Simulation Results...............................................................................................................33
Conclusion.....................................................................................................................................41
REFERENCES..............................................................................................................................42
 List of Figures
Figure 1:Centrifugal PumpFigure....................................................................................................5
.Figure 2:Types of Impellar.............................................................................................................6
Figure 3::Impellar Types.................................................................................................................7
Figure 4:Centrifugal pump..............................................................................................................9
Figure 5:2d drawing of centrifugal pimp.......................................................................................26
Figure 6:Centrifugal pump SOLIDWORKS CAD MODEL.........................................................26
Figure 7:Static pressure and velocity distribution for 2300 rpm for Aluminium alloy 6061........34
Figure 8:Static pressure and velocity distribution for 2300 rpm for E-Glass / Epoxy..........35
Figure 9:Static pressure and velocity distribution for 2500 rpm for Aluminium alloy 6061........36
Figure 10:Static pressure and velocity distribution for 2500 rpm for E-Glass / Epoxy........37
Figure 11:Static pressure and velocity distribution for 2880 rpm rpm for Aluminium alloy 6061
....................................................................................................................................................... 38
Figure 12:Static pressure and velocity distribution for 2880 rpm for E-Glass / Epoxy........39
Chapter 1

Introduction
The application of fluid machinery has spread its wings in all aspects of human life. The usage of
pumps extends to domestic services, commercial and agricultural services, municipal
water/wastewater services, and industrial services such as food processing. Pumps are also used
in chemical, petrochemical, pharmaceutical and mechanical industries. This chapter deals with
the classification of the pumps, and the selection of the pumps based on their applications and
their operating principles.

1.1 CLASSIFICATION
In general, pumps are classified into Positive Displacement Pumps and Centrifugal Pumps based
on their working principles

Positive Displacement Pumps

A positive displacement pump operates by alternately filling a cavity and then displacing a given
volume of liquid. The positive displacement pump delivers a constant volume of liquid against
varying discharge pressure or head.

Single Rotor Pumps

Vane - The vane/vanes may be blades, buckets, rollers or slippers which cooperate with a dam to
draw fluid into and out of the pump chamber.

Piston - Fluid is drawn in and out of the pump chamber by a piston/pistons reciprocating within a
cylinder /cylinders and operating port valves.

Flexible Member - Pumping and sealing depend on the elasticity of a flexible member/members
which may be a tube, vane or a liner.

Single Screw - Fluid is carried between rotor screw threads as they mesh with internal threads on
the stator.

Progressing Cavity - Fluid is carried between a rotor and a flexible stator

Multiple Rotor Pumps

Gear - Fluid is carried between gear teeth and is expelled by the meshing of the gears which
provide continuous sealing between the pump inlet and outlet.

Lobe - Fluid is carried between rotor lobes which provide continuous sealing between the pump
inlet and outlet.

Circumferential Piston - Fluid is carried in spaces between piston surfaces not requiring contacts
between rotor surfaces.

Multiple Screw - Fluid is carried between rotor screw threads as they mesh.

1.2 Centrifugal Pumps

Centrifugal pumps can be classified based on the manner in which fluid flows through the pump. The
manner in which fluid flows through the pump is determined by the design of the pump casing and the
impeller. The three types of flow through a centrifugal pump are radial flow, axial flow, and mixed flow

Figure 1:Centrifugal PumpFigure

Radial Flow
In a radial flow pump, the liquid enters at the center of the impeller and it is directed out along
the impeller blades in the direction at right angles to the shaft of the pump in which the pressure
is developed wholly by centrifugal force. When the head requirement is more, radial flow pumps
are preferred.

Axial Flow

In an axial flow pump, the impeller pushes the liquid in the direction parallel to the pump shaft in
which the pressure is developed by the propelling or lifting action of the vanes of the impeller on
the liquid. Axial flow pumps are sometimes called propeller pumps because they operate
essentially as the propeller of a boat does. When more flow rate is required, axial flow type
pumps are preferred.

Mixed Flow

In a mixed flow pump, the flow direction is mixed. In this the pressure is developed partly by
centrifugal force and partly by the lift of the vanes of the impeller on the liquid. These pumps are
used for medium head and medium flow applications

Impeller type

Impellers are classified into Single-Suction Impeller and Double Suction Impeller based on the
number of points the liquid can enter the impeller and also on the amount of webbing between
the impeller blades as shown in Figure 2. A single-suction impeller allows the liquid to enter the
center of the blades from only one direction. A double-suction impeller allows liquid to enter the
center of the impeller blades from both sides simultaneously.

.Figure 2:Types of Impellar

Impellers can also be classified into open, semi-open and enclosed types as shown in Figure .
The open impeller consists only of blades attached to a hub, which are used for transporting
semi-solid particles. The semi-open impeller is constructed with a circular plate (the web)
attached to one side of the blades and is used for carrying slurry. The enclosed impeller has
circular plates attached to both sides of the blades. Enclosed impellers are also referred to as
shrouded impellers, which are useful for transporting high head fluid.

Figure 3::Impellar Types

Radial flow impellers develop head through centrifugal force. Radial impellers are low flow high
head designs. Pumps of higher specific speeds develop head partly by centrifugal force and
partly by axial force. A higher specific speed indicates a pump design with head generation more
by axial forces and less by centrifugal forces. An axial flow or a propeller pump with a specific
speed of 10,000 or greater generates its head exclusively through axial forces. Axial flow
impellers are of high flow, low head designs.

• Specific speed (Ns) identifies the approximate acceptable ratio of the impeller eye diameter
(D1) to the impeller maximum diameter (D2) in designing an impeller:

• Ns 500 to 5000 D1/D2 > 1.5 - radial flow pump

• Ns 5000 to 10000 D1/D2 < 1.5 - mixed flow pump

• Ns 10000 to 15000 D1/D2 = 1 - axial flow pump

1.3 SELECTION OF A PUMP
Selecting between a centrifugal pump and a positive displacement pump is not always an easy
task. The following are the various parameters which influence their selection.

Flow Rate and Pressure Head These two types of pumps behave very differently regarding
pressure head and flow rate:

• The centrifugal pump has varying flow depending on the system pressure or head.

• The positive displacement pump has more or less a constant flow regardless of the system
pressure or head. Generally it gives more pressure than a Centrifugal pump.

Capacity and Viscosity

Another major difference between the two pumps is the effect of viscosity on their capacity:

• In the centrifugal pump the flow is reduced when the viscosity is increased.

• In the positive displacement pump the flow is increased when viscosity is increased.

• Liquids with high viscosity fill the clearances of a positive displacement pump causing a
higher volumetric efficiency and so a positive displacement pump is better suited for high
viscosity fluid applications. A centrifugal pump becomes very inefficient at even modest
viscosity.

1.4 CENTRIFUGAL PUMP

A Centrifugal Pump is a machine that transports the fluid from low head to high head by the
conversion of kinetic into pressure energies. It operates by creating pressure difference between
the suction side and delivery side of the pump. Its purpose is to convert the energy of a prime
mover (an electric motor or turbine) first into velocity or kinetic energy of the fluid, and then into
pressure energy of a fluid that is being pumped. The energy changes occur by virtue of two main
parts of the pump, the impeller and the volute or diffuser, as shown in Figure 4. The impeller is
the rotating part that converts driver energy into kinetic energy. The volute or diffuser is the
stationary part that partly converts the kinetic energy into pressure energy
Figure 4:Centrifugal pump

The liquid enters the suction nozzle and then into eye (center) of a revolving device known as an
impeller. When the impeller rotates, it spins the liquid sitting in the cavities between the vanes
outward and provides centrifugal acceleration. As the liquid leaves the eye of the impeller, a
lowpressure area is created causing more liquid to flow towards the inlet. Because the impeller
blades are curved, the fluid is pushed in a tangential and radial direction by the centrifugal force.
This force acting inside the pump is the same one that keeps water inside a bucket that is
revolving at the end of a string. Figure 1.9 depicts a side cross-section of a centrifugal pump
indicating the movement of the liquid.

When liquid is forced away from the centre, a vacuum is created and consequently more liquid
flows in. Thus continuous lifting of liquid takes place from the sump to the pump. While passing
through the impeller, the liquid receives energy from the vanes, and gains in pressure energy and
kinetic energy. Since large amount of kinetic energy is not desirable at the impeller outlet,
arrangement is made in design to convert the kinetic energy of the liquid into pressure energy
before the liquid enters the discharge pipe. The amount of energy given to the liquid is
proportional to the velocity at the edge or vane tip of the impeller. The faster the impeller
revolves or the bigger the impeller is the higher will be the velocity of the liquid at the vane tip
and the greater the energy imparted to the liquid. This kinetic energy of a liquid coming out of an
impeller is harnessed by creating a resistance to the flow. The first resistance is created by the
pump volute (casing) that catches the liquid and slows it down. In the discharge nozzle, the
liquid further decelerates and its velocity is converted into pressure according to Bernoulli’s
principle.

Whenever flow takes place from a low-pressure region to a highpressure one, there is a
possibility of separation. In the case of sudden expansion, there is a danger of water particles
separating out from mainstream and trying to flow back resulting in the formation of eddies.
Thus separation takes place which, in turn, causes heavy energy loss and reduces the pump
efficiency.

1.5 Applications of the Centrifugal Pump

The pump services in all sectors of the Industry viz. Agriculture, Public Health Engineering,
Water Supply, Chemical and Process industries, Refinery and Petrochemical industries, Paper,
Steel and Mining industries, Power Generation, Food Processing, Pharmaceutical industries,
Sewage and Effluent treatment etc. Around 80% of the world’s energy is consumed in running
different forms of pumps, fans and blowers.

Although pumps are typically purchased as individual systems, they provide a service only when
operating as a part of a piping system. The energy and materials used by a pump system depend
on the design of the pump, the design of the installation and the way the system is operated.
These factors are interdependent. What is more, they must be carefully matched with each other,
and remain so throughout their working lives so as to ensure the lowest energy and maintenance
costs, longer equipment life, and other benefits. The maximum working efficiency of all the
pumps is less, and a lot of energy is wasted as a result of this. Large quantum of energy can be
saved by way of increasing the efficiency of these pumps. Conventionally, many aspects of the
design of impeller are based on empirical formulae derived from experience and thumb rules.
Therefore, studying the parameters scientifically will serve the dual purpose of increasing the
efficiency and also establishing a scientific method of designing the impeller.
1.6 Composite materials
The development of composite materials as well as the related design and manufacturing
technologies is one of the most important advances in the history of materials. Composites are
multifunctional materials having unprecedented mechanical and physical properties which can be
tailored to meet the requirements of a particular application. Many composites also exhibit great
resistance to wear, corrosion, and high-temperature exposure. These unique characteristics
provide the mechanical engineer with design opportunities not possible with conventional
monolithic (unreinforced) materials. Composites technology also makes possible the use of an
entire class of solid materials, ceramics, in applications for which monolithic versions are
unsuited because of their great strength scatter and poor resistance to mechanical and thermal
shock. Further, many manufacturing processes for composites are well adapted to the fabrication
of large, complex structures, which allows consolidation of parts, reducing manufacturing costs.

Composites are important materials which are now used widely, not only in the aerospace
industry, but also in a large and increasing number of commercial mechanical engineering
applications, such as internal combustion engines; machine components; thermal management
and electronic packaging; automobile, train, and aircraft structures and mechanical components,
such as brakes, drive shafts, flywheels, tanks, and pressure vessels; dimensionally stable
components; process industries equipment requiring resistance to high-temperature corrosion,
oxidation, and wear; offshore and onshore oil exploration and production; marine structures;
sports and leisure equipment; ships and boats; and biomedical devices. It should be noted that
biological structural materials occurring in nature are typically some type of composite.
Common examples are wood, bamboo, bone, teeth, and shell. Further, use of artificial composite
materials is not new. Straw-reinforced mud bricks were employed in biblical times. Using
modern terminology, discussed later, this material would be classified as an organic fiber-
reinforced ceramic matrix composite.
1.7 PROPERTIES AND APPLICATIONS OF COMPOSITE MATERIALS
There are a large and increasing number of materials in all four classes of composites: PMCs,
MMCs, CMCs, and CAMC. CCCs are the most important type of carbon matrix composites at
this time. In this section, we present properties of key materials in each class. We also consider
the properties of advanced composites and other advanced materials used in electronic and
photonic thermal management. Initially, the excellent mechanical properties of composites were
the main reason for their use. However, there are an increasing number of applications for which
the unique and tailorable physical properties of composites are key considerations. For example,
the extremely high thermal conductivity and tailorability CTE of some composite material
systems have led to their increasing use in electronic and photonic thermal management and
packaging. Similarly, the extremely high stiffness, near-zero CTE, and low density of carbon
fiber-reinforced polymers have made these composites the materials of choice in spacecraft
structures, optical systems, antennas, and other applications for which dimensional stability is
important.
Chapter 2

Literature Review
Lazarkiewicz Stepen (1965) has explained the procedure to calculate the dimensions of the
impeller and has also discussed various methods for determining the shape of the impeller
blades, which are referred to by the designers. The effects of the individual parameters that
influence the performance of the impeller were studied by the authors Lobanoff (1985) and
Stepanoff (1948)

Van Esch (1997) in his thesis has shown that the flow in hydraulic pumps of the radial and mixed
flow type, operating at conditions not too far from design point, can be considered as an
incompressible potential flow, where the influence of viscosity is restricted to thin boundary
layers, wakes and mixing areas. He also concluded that the design of hydraulic turbo machines
has reached the stage where improvements can be achieved only through a detailed
understanding of the internal flow. The internal flow structure in a centrifugal pump impeller is
complex, involving streamline curvature, system rotation, separation and turbulence effects.

Pedersen et al (2003) has done an exhaustive study to visualize the flow in the centrifugal pump
impeller and his research outcome provides a detailed instantaneous data of the impeller flow
field in the rotating passage of a centrifugal pump impeller.

Lazarkiewicz Stepen (1965) has explained the procedure to calculate the dimensions of the
impeller and has also discussed various methods for determining the shape of the impeller
blades, which are referred to by the designers. The effects of the individual parameters that
influence the performance of the impeller were studied by the authors Lobanoff (1985) and
Stepanoff (1948).
Frost and Nilsen proposed a simple model for estimating the contribution of the volute to the
shut-off head of a centrifugal pump or fan. The model is based on an assumed linear distribution
of tangential velocity in the plane of the cutwater, which satisfies approximately the continuity
condition of zero net flow into the outlet duct. The contribution of the impeller is assumed to be
that given by a solid body rotation at the angular velocity of the pump from the bore of the inlet
duct to the impeller tip. The simple radial equilibrium equation is then used to calculate the static
head rise in both the impeller and volute. The resultant prediction of shut-off head has been
compared to test data on various pump series made available by courtesy of two European
manufacturers. In all of the series, the impeller diameter has been varied between 100 and 90 to
80 percent of its design value and has been tested in the designed volute. Since a review of the
available literature did not show any previous work of a fully consistent nature on this topic, the
proposed model as described in detail is offered as a fairly accurate prediction technique for
design purposes.

Ishida, Ueki and Senoo highlighted secondary flow occurrence. According to the theory
presented by the authors, the tip clearance loss of an unshrouded centrifugal impeller mainly
consists of two kinds of losses, one is the drag due Chapter – 2: Literature Review and
Objectives of Present Work “Studies on Radial Tipped Centrifugal Fan” 35 to the leakage flow
through the blade tip clearance and the other one is the pressure loss to support the fluid in the
thin annular clearance space between the shroud and the blade tip against the pressure gradient in
the meridional plane without blades. The former is proportional to the leakage flow orthe
contraction coefficient of leakage flow. The authors have conducted performance tests using an
impeller with 16 backwardleaning blades in three blade tip configurations having round edge,
sharp square edge, and edge with an end-plate. The experimental tip clearance effects can be
predicted by assuming reasonable contraction coefficients 0.91, 0.73, and 0.53, respectively. The
impeller efficiency is improved by 1.5% by reducing the contraction coefficient from 0.91 to
0.53, providing that the tip clearance ratio at the exit ofimpeller is 0.1.

Kind and Tobin concluded that large values of rotor exit to inlet area ratio of fans results in
separation of the incoming flow. This paper presents the results of performance measurements of
the mean flow field at rotor inlet and rotor exit for three squirrel-cage fan configurations. The
flow-field measurements were taken with a fivehole probe for total pressure, static pressure, and
the three components of velocity. Measurements were taken for two different casing throat areas
and rotors. For each set of configuration, flow rate was measured in the vicinity of best
efficiency point. Flow patterns are complex and the reverse flow through the rotor blades was
observed even at the best-efficiency operating condition. This was similar to all fan
configurations under study.

Sideris and Braembussche presented a set of detailed experimental data describing the impeller
response to a circumferential variation of the outlet pressure. These data reveals that the outlet
volume influences the flow inside the impeller through the static pressure variation at the
impeller exit and signifies the need of re-evaluation of theoretical prediction methods. It
describes the advantages and disadvantages of the different geometries, the relation between
flow and geometry, and the impact on the downstream or upstream of impeller, the loss
mechanisms and some loss prediction models are presented. The main purpose of this study is to
provide an insight into the flow structure that can be used later to improve the performance or
remediate design problems. The use of CFD is not discussed here but the flow models presented
here may help to get a better understanding of the CFD output.

William C. Osborne has made very good attempt to use simple flow physics to design
fans/blowers. He has used empirical relations for eye velocity, meridian velocity and casing
velocity with respect to impeller tip peripheral velocity. Relative velocity is considered same for
inlet and outlet conditions. This is one of the major limitations of this design. Suction, impeller,
volute pressure losses and leakage losses are calculated separately. He said that the purpose of
fan is to move air/gas continuously against moderate pressures. Although, a little compression
may occur, it is customary to consider fan as incompressible fluid machine. Osborne has used
circular arc method to construct centrifugal fan blade profile. Blade profile construction
methodology is described as under.

Sane and Shevare dealt with the design of radial impeller through the superposition of two flows.
The first being the flow in an impeller with the infinite number of blades, obtained directly as a
solution of Navier Stoke’s equations for axisymmetric, incompressible and inviscid flow. The
second being a potential perturbation due to finite number of blades with the first flow as the
onset flow.
Patel, Patel and Shah presented the method, which gives the range of design constants and rapid
selection for optimum design. The specified design method is wide enough to cover the complete
range of centrifugal pumps. The method can be easily computerized. The actual test performance
of pumps designed by this method lies within acceptance limits.

Austin Church has done pioneering work to establish design methodology for pumps, fans and
blowers. He found that the type of flow existing in a pump or blower is always turbulent, it
means, the Reynolds number is always well above the critical value. The flow is seriously
disturbed with a resultant loss of head. He has presented his design with stage compressibility
effect, pressure ratio and energy transfer. He has also considered density changes at various flow
sections with respect to change in temperature and pressure. Thus volume flow rate gets changed
continuously. The dimensions of the air passage are calculated in accordance to this variation in
volume flow. Stage pressure ratio between atmosphere to inlet eye, inlet eye to impeller inlet,
impeller inlet to impeller outlet and impeller outlet to casing outlet are calculated individually

Stodola had developed first useful method for slip factor approximation. He correlated slip factor
and finite number of blades. Stodola claimed that average direction of discharge varies from the
blade angle β2 due to number of blades and relative circulation in vane to vane plane. This is
also responsible for the reduction in output. Several co-relations as well as empirical equations
are used in literature to estimate slip factor. Other slip factor correlations in literature are given
by Balje, Stanitz and Eck Bruno . According to all these researchers, the major cause of slip are
due to relative eddies generated in vane to vane plane. These correlations conclude that for a
given specified machine, the value of slip factor is constant and is dependent of Impeller
geometry only

During this period, W. J. Kearton observed breaks in characteristic curves by carrying accurate
tests. His measurements indicated that the flow is far from uniform, and that on the trailing face
of the vane there is an area of “inactive flow”. This area increases as the capacity is reduced. The
effect of this inactive flow is equivalent to increasing the vane thickness and reducing the
passage area. He had noticed that number of impeller blades has significant effect on fan
performance curves.
W. J. Kearton investigated these conditions and has presented his findings in a very interesting
paper, “Influence of the Number of Impeller Blades on the Pressure Generated in a centrifugal
compressor and on its General performance.” He also found that below the critical flow the
velocity distribution was fairly symmetrical and resembled the velocity distribution obtained
with turbulent flow in a pipe. Above the critical flow the velocity distribution was not
symmetrical, but much greater on the side of the impeller away from the inlet.

Leonardo Da Vinci (1452-1519) was probably the first to coin the idea of lifting water by
centrifugal forces. He has described primitive models of turbo machines by making some
sketches. From his original sketches, a French physicist Denis Papin was first to describe the
centrifugal pump scientifically in 1687. He built first pump in 1705, which had impeller with
blades and a volute. Thus, centrifugal pumps and blowers of today are made after more than 300
years’ of revolution.

Van Esch (1997) in his thesis has shown that the flow in hydraulic pumps of the radial and mixed
flow type, operating at conditions not too far from design point, can be considered as an
incompressible potential flow, where the influence of viscosity is restricted to thin boundary
layers, wakes and mixing areas. He also concluded that the design of hydraulic turbo machines
has reached the stage where improvements can be achieved only through a detailed
understanding of the internal flow.

Jorge L. Parrondo-Gayo (2000) has presented an experimental study on the unsteady pressure
field around the outlet of the impeller of an industrial centrifugal pump with volute casing. He
summarized that the fluctuating pressure field in the volute at the blade passage frequency may
be interpreted to result from the disturbances associated with the passage of each blade in front
of each point of the volute and with the passage of each blade in front of the tongue. He also
ensured that the effect of blade-tongue interaction is particularly important for off-design
condition.
unaveikko Ala Juusela (2001) compares the numerical simulation of flow in centrifugal process
pumps using k-ω and k-ε turbulence models and also compares the results of the inviscid
approximation with the turbulence models. In the inviscid case, the efficiency is quite different
from the experimental results. He stressed the need for using a turbulence model and in particular
k-ε turbulence model. It is also stated in that most of the turbulent flow application, k-ε
turbulence model is being used.

The internal flow structure in a centrifugal pump impeller is complex, involving streamline
curvature, system rotation, separation and turbulence effects. Pedersen et al (2003) has done an
exhaustive study to visualize the flow in the centrifugal pump impeller and his research outcome
provides a detailed instantaneous data of the impeller flow field in the rotating passage of a
centrifugal pump impeller.

E.C. Bacharoudis, A.E. Filios, M.D. Mentzos and D.P. Margaris (2008) in this study, the
performance of impellers with the same outlet diameter having different outlet blade angles is
thoroughly evaluated. The One-dimensional approach along with empirical equations is adopted
for the design of each impeller. The predicted performance curves result through the calculation
of the internal flow field. Head-discharge curve play important role into different outlet angles.
The influence of the outlet blade angle on the performance is verified with the CFD. The
performance curve becomes smoother and flatter with the increase with the increase outlet blade
angle. At nominal capacity, when the outlet blade angle was increased from 20° to 50°, the head
was increased by more than 6% but the hydraulic efficiency was reduced by 4.5%. However, at
high flow rates, the increase of the outlet blade angle caused a significant improvement of the
hydraulic efficiency

LIU Houlin, WANG Yong, YUAN Shouqi, TAN Minggao, and WANG Kai (2010) Blade
number play the important role during designing the pump which affects the characteristics of
the pump. The model pump has a design specific speed of 92.7 and an impeller with 5 blades.
The blade number is varied to 4, 6, 7 with the casing and other geometric parameters keep
constant. The inner flow fields and characteristics of the centrifugal pumps with different blade
number are simulated and predicted in noncavitation and caviation conditions by using
commercial code FLUENT. Using rapid prototyping the impeller with different blade numbers is
made. With the increase of blade number, the area of low pressure region at the suction of blade
inlet grows continuously, and the uniformity of static pressure distribution at screw section
become worse and worse while at diffusion section become better and better. The head of model
pump is increase with the increase with pump but there is variation with efficiency and cavitation
is complicated. These results are important to design of the centrifugal pump

B.Mohan, B.E.Kumar (2011) the novel axial composite impeller has been developed using
commercial tools pro-e. They have chosen the suitable materials for this study, namely Kevlar-
49, Carbon and S-Glass with a standard epoxy resin for the composite matrix. Static and
dynamic behaviors of the component were analyzed using finite element analysis commercial
tool ANSYS 14.5. They have analyzed the stress distributions and displacements on the
composite impeller in static analysis. The stress concentration regions were identified in this
analysis. For transient analysis, we have applied dynamic force at various operating speeds of the
impeller and analyzed the deflections and stress concentration regions

S.Rajendran, Dr.K.Purushothaman (2012) described the simulation of the flow in the impeller of
a centrifugal pump. The analysis of centrifugal pump impeller design is carried out using
ANSYS-CFX. The complex internal flows in Centrifugal pump impellers can be well predicted
through ANSYS-CFX. The numerical solution of the discredited three-dimensional,
incompressible Navier-Stokes equations over an unstructured grid is accomplished with an
ANSYS-CFX

A Syam Prasad, BVVV Lakshmipathi Rao, A Babji, Dr P Kumar Babu (2013) It described the
static and dynamic analysis of a centrifugal pump impeller which is made of three different alloy
materials (viz., Inconel alloy 740, Incoloy alloy 803, Warpaloy) to estimate its performance. The
investigation has been done by using CATIA and ANSYS13.0 softwares. A structural analysis
has been carried out to investigate the stresses, strains and displacements of the impeller and
modal analysis has been carried out to investigate the frequency and deflection of the impeller.
An attempt is also made to suggest the best alloy for an impeller of a centrifugal pump by
comparing the results obtained for three different alloys

Neelambika, Veerbhadrappa (2014) a detailed CFD analysis was done to predict the flow pattern
inside the impeller which is an active pump component. The optimum inlet and outlet vane
angles are calculated for the existing impeller by using the empirical relations. In the first case,
outlet angle is increased by 5°. From the outlet flow conditions, obtained from the CFD analysis,
it is evident that the reduced outlet recirculation and flow separation cause the improved
efficiency. By changing the outlet angle the efficiency of the impeller is improved to 59%. In the
second case inlet angle is decreased by 10%. The efficiency of the impeller in this case is 61%.
From this analysis it is understood that the changes in the inlet vane angle did not change the
efficiency of the impeller as much as the changes in outlet angle. The existing impeller, the head
and efficiency are found out to be 19.24 m and 55% respectively. The impeller 1, the percentage
increase in the head and efficiency are 3.22% and 7.27% respectively. The impeller 2, the
percentage increase in the head and efficiency are 10.29% and 10.91% respectively. The impeller
3, the percentage increase in the head and efficiency are 13.66% and 18.18% respectively. Based
on the above, it is concluded that impeller 3 gives better performance

Santosh Shuklaa, Apurba Kumar, Royband Kaushik Kumar (2015) highlight to minimize the
stress developed and deformation. The 3D model of mixed flow pump impeller blade was
developed using CATIA and with four different materials (Copper alloy, Bronze, Stainless steel
and Titanium alloy) analysis was done in ANSYS 11.0 with similar loading and support
conditions. The results obtained were compared. It was observed that Titanium alloy can be
considered as the constructional material for the blades as it gave minimum deformation (at Tip)
and Stress (at base).

Basavraj, H.Hasu (2016): In this paper, the analyze the centrifugal pump with the change in the
vane angle. The model pump changes the vane angle with 16,8,20 deg. Static analysis and Modal
analyses are performed on the impeller to determine stresses, deformations and frequencies by
applying the rotational velocity for different materials. By observing the structural analysis
results, the deformation and stress values are slightly varying by varying the blade angles. By
observing model analysis results, CFRP has more frequency value. The vibrations are more
when CFRP is used and the frequency and deformation values are less when Stainless Steel is
used. So CFRP is better material. CFD analysis is done by applying the velocity of fluid to
determine pressures developed mass flow rates.

An alternative (and historically earlier) approach to aerodynamic shape design is given by

inverse methods for aerofoil shape. Since the pump impeller vane profile is also similar to that of
aerofoil shape, the inverse design method is tried in this work by considering suitable physics.
This class includes analytical and numerical methods for improving the aerodynamic
performance of a device by controlling a physical quantity (such as static pressure, speed and or
swirl distribution) along the unknown sidewalls. The inverse procedure determines the geometry
along with the corresponding flow field. The inverse design is an approach through which the
shape is realized from the specified pressure or velocity distribution. The inverse method is
classified into iterative use of direct inverse method and the true inverse method. By the iterative
use of direct method, the shape is optimised by trials. The optimised shape is analysed using
direct method and the results are compared with the desired one. The deviation, the error which
is identified by this way, is used to construct the new geometry for the next trial. But in the true
inverse method, the final shape is determined directly through a series of iterations.

Larosliere and Praht (1997) have explained the parametric design study to improve the
flow quality. Significant progress has been made in understanding impeller aerodynamic
performance and also in predicting certain local flow fields. But still the question of finding out
which is the most effective variable to improve the efficiency of a pump, is unresolved. Kelder et
al (2001) have made comprehensive measurements on both velocity and pressure in a low
specific speed centrifugal pump. Gray (1999], de Vito et al (2003), Kim and Park (1999),
Thomas W. Bein (2001] and Westra, et al (2005) have proposed the inverse operation in which
the specified velocity or pressure will compute the shape of the geometry needed to be achieved
by direct approach

Stanitz et al (1953), (1980) developed an inverse method for twoand three-dimensional

potential flows. The idea is to use a pair of stream functions ψ(x, y, z), η(x, y, z) and a potential
function (so-called natural coordinate) φ(x, y, z) as independent variables. The governing flow
equations (potential equation and equation for the density) are expressed in terms of these new
coordinates, leading to a particularly simple formulation. Mass conservation is satisfied
implicitly by the use of stream functions. The remaining equations involve the metric of the
mapping x(ψ,η,φ). This method has been extended to rotational homo entropic flow by Zannetti
et al (1986), (1993), (1993), (1995) and (1995), Keller (1998) and (1999), Scascighini (2003).
These methods differ mainly by the choice of unknown variables and in the imposed data.

Junaveikko Ala Juusela (2001) compares the numerical simulation of flow in centrifugal process
pumps using k-ω and k-ε turbulence models and also compares the results of the inviscid
approximation with the turbulence models. In the inviscid case, the efficiency is quite different
from the experimental results. He stressed the need for using a turbulence model and in particular
k-ε turbulence model. It is also stated in that most of the turbulent flow application, k-ε
turbulence model is being used.
Jorge L. Parrondo-Gayo (2000) has presented an experimental study on the unsteady pressure
field around the outlet of the impeller of an industrial centrifugal pump with volute casing. He
summarized that the fluctuating pressure field in the volute at the blade passage frequency may
be interpreted to result from the disturbances associated with the passage of each blade in front
of each point of the volute and with the passage of each blade in front of the tongue. He also
ensured that the effect of blade-tongue interaction is particularly important for off-design
condition.

Fernández, Joaquín (2003) has presented an experimental and numerical study on the unsteady
radial forces produced in a centrifugal pump with volute casing with radial gap variation. He
analyzed the steady and unsteady forces at the blade passing frequency obtained by radial
integration of the pressure distributions in the shroud side of the pump volute in detail, and
obtained similar trends.

Champagne has presented the results of Laser Doppler Anemometry (LDA) investigation of the
internal flow of a centrifugal pump equipped with a backswept impeller and a vaned diffuser.
The unsteadiness of the flow at the leading edge of a vaned diffuser represents a source of low
efficiency and instability in a centrifugal pump. He has concluded that the impeller-diffuser
interaction is limited to the impeller exit, and it does not have any upstream influence on the
flow.

Johnson (1996) has explained the experimental measurements in a centrifugal pump impeller. He
found a significant leading edge loss, associated with the separation of the boundary layer near
the pressure side shroud corner. He believes that a better understanding of centrifugal pump
impeller flows can lead to improved performance with associated reduction in operating costs.
Drallmeier (1996) has discussed in his work the pump 28 experiment to determine the typical
operating characteristics of a pump and to understand the instrument accuracy and design error
analysis.

Selecting a suitable turbulence model for turbo machinery simulations is a challenging task.
There is no single model which is suitable for all types of simulations which turbulence model
CFD engineers use has as much to do with beliefs and traditions as with knowledge and facts.
However, below follows some guidelines that most CFD engineers in the turbo machinery field
tend to agree upon.
For attached flows close to the design point a simple algebraic model like the Baldwin-Lomax
model can be used. Another common choice for design-iteration type of simulations is the one-
equation model by SpalartAllmaras. The big advantage with both the Baldwin-Lomax model and
the Spalart-Allmaras model over more advanced models is that they are very robust to use and
rarely produce completely unphysical results.

In order to accurately predict more difficult cases, like separating flows, rotating flows, flows
affected by secondary flows etc. it is often necessary to use a more refined turbulence model.
Common choices are twoequation models like the k-epsilon model.

The K-epsilon model is one of the most common turbulence models. It is a two equation
model that means, it includes two extra transport equations to represent the turbulent properties
of the flow. This allows a equation model to account for history effects like convection and
diffusion of turbulent energy. The first transported variable is turbulent kinetic energy, k. The
second transported variable in this case is the turbulent dissipation, epsilon. It is the variable that
determines the scale of the turbulence, whereas the first variable, k, determines the energy in the
turbulence.

the ultimate goal of hydrodynamic shape design is not only to produce better devices, but
also to reduce development time. The design process should require minimal human interaction
and as little expert knowledge as possible. There seems to be a trade-off between implementation
and run-time work. From the practical point of view, methods employing existing analysis codes
as a black box, are favourable for various reasons. The effort of implementation, documentation
and validation is greatly reduced. Furthermore, off-design studies can be performed using the
same code. On the other hand, performance in terms of CPU time is often poor compared to
approaches requiring a totally new and highly specialised code. An intermediate option is
provided by approaches based on a tight nesting of analysis and design loop at the cost of
interacting with the available code.
2.1 OBJECTIVES OF THE PROPOSED WORK
The aim of this thesis is to propose a computational tool for hydrodynamic design of centrifugal
pump impeller.

The objective of this work is to

• Optimize the impeller design,

 Static and dynamic analysis on centrifugal pump impeller balde is carried out to evaluate
performance at different load conditions
• Validate the design by experiment, with different types composite materials
• Simulate the design to validate and get the insight of the approach
Chapter 3

MethodologyType equation here .

3.1 Modelling
MATHEMATICAL CALCULATION FOR THE CASE STUDY

1. Calculate pump specific speed

1450* √ (1000/3600)
Ns   48.07460RPM
403/4

2. Calculate the input and output power

Po  1000* 9.806* 40 * 0.2778 109kW

Ps 109/ 0.86 126.7kW say 127kW

3- Calculate input torque to pump

T=127000*60/2*3.14*1450 =837 N.m

4-Calculate the shaft diameter

16 * 837
d  47.05mm say 50mm

 40000000
Figure 5:2d drawing of centrifugal pimp

Figure 6:Centrifugal pump SOLIDWORKS CAD MODEL

3.2 Materials
Aluminium alloy 6061

Density 2.7 g/cm³

Tensile strength 124–290 MPa
Melting Temperature 585 °C
 Thermal conductivity 151–202 W/(m·K)

E-Glass / Epoxy

Density 1.90 g/cm³

Tensile strength 490 MPa
Melting Temperature 177 °C
Thermal conductivity 0.15-0.25 W/(m·K)

Testing the performance of a pump using conventional and experimental method is time
consuming and costly. It takes a long time to approve a design, if we make multiple proto type
and then test each of them. Instead, simulation is used to find the performance of an impeller and
casing using Computational Fluid Dynamics software. Once the flow pattern and performance
are satisfactory, then we can go for one or two types to validate the simulation results.

Initially it deals with the modelling approach of the pump. The simulation is carried out for
different speeds with varying operating conditions. Then the simulation results are compared with
the experimental results for the same operating conditions to confirm the suitability of this
approach.
3.3 ANALYSIS OF FLUID FLOW DOMAIN
The prediction of flow is very complicated due to the rotation and curved three-dimensional
shape of impellers. In order to know more about the flow pattern, simulation of flow is essential.
The simulation can be carried out by commercially available computational fluid dynamic
packages.

The objective of the simulation is to study the detailed distribution of the flow parameters. The
simulation procedure should be established with the experimental results for an available pump,
and can be extended to the new design modifications. The simulation results provide a better
insight to the designer by doing parametric studies. The experiment compliments the simulation
results. This is helpful for fixing the simulation parameters and based on these parameters, the
modified designs are validated. This reduces the number of trials, which ultimately reduces the
time and cost for the development.

3.3.1 Introduction to CFD

Computational Fluid Dynamics (CFD) has grown from a mathematical curiosity to become an
essential tool in almost every branch of fluid dynamics, from aerospace propulsion to weather
prediction. CFD is commonly accepted as referring to the broad topic encompassing the
numerical solution, by computational methods. These governing equations, which describe fluid
flow, are the set of Navier-Stokes equation, continuity equation and any additional conservation
equations, for example, energy or species concentrations.

Since the advent of the digital computer, CFD, as a developing science, has received extensive
attention throughout the international community. The attraction of the subject is two fold.
Firstly, there is the desire to be able to model physical fluid phenomena that cannot be easily
simulated or measured with a physical experiment, for example, weather systems. Secondly,
there is desire to be able to investigate physical fluid systems more cost effectively and more
rapidly than with experimental procedures.

Traditional restrictions in flow analysis and design limit the accuracy in solving and visualization
of the fluid-flow problems. This applies to both single and multi-phase flows, and is particularly
true of problems that are three dimensional in nature and involve turbulence, chemical reactions,
and/or heat and mass transfer. All these can be considered together in the application of CFD, a
powerful technique that can help to overcome many restrictions inherent in traditional analysis.
CFD is a method for solving complex fluid flow and heat transfer problems on a computer. CFD
allows the study of problems that are too difficult to solve using classical techniques. The flow
path inside the impeller of the centrifugal pump is intricate and this can be analyzed using CFD
tool, which provides an insight into the complex flow behavior.

The process of performing CFD simulations is split into three components:

Setting up the simulation : Pre - processing (interactive) Solving for the flow field : Solver (non -
interactive / batch process)

Pre-processing

The pre-processor contains all the fluid flow inputs for a flow problem. It can be seen as a user-
friendly interface and a conversion of all the input into the solver in CFD program. At this stage,
quite a lot of activities are carried out before the problem is being solved. These stages are listed
below

Geometry Definition - The region of interests, that is the computational domain which has to be
defined.

Grid generation- It is the process of dividing the domain into a number of smaller and non-
overlapping sub-domains.

Physical and chemical properties - The flow behavior in terms of physical and chemical
characteristics are to be selected.

Fluid property Definition - The fluid properties like density and viscosity are to be defined.

Boundary conditions - All the necessary boundary conditions have to be specified on the cell
zones.

The solution of the flow problem such as temperature, velocity, pressure etc. is defined at the
nodes insides each cell. The accuracy of the CFD solution is governed by the number of cells in
the grid and is dependent on the fineness of the grid.
Solution
In the numerical solution technique, there are three different streams that form the basis of the
solver. There are finite differences, finite element and finite volume methods. The differences
between them are the way in which the flow variables are approximated and the discretization
processes are done.

FVM was originally developed as a special finite difference formulation. The main
computational commercial CFD codes packages using the FVM approaches involves Phoenics,
Fluent, Flow 3D and Star-CD. Basically, the numerical algorithm in these CFD commercial
packages involves the formal integration of the governing equation over all the finite control
volume, the discretization process involves the substitution of a variety of FDM types to
approximate the integration equation of the flow problem, and the solution is obtained by
iterative method. Discretization in the solver involves the approaches to solve the numerical
integration of the flow problem. Usually, two different approaches are made, one at a time

Post-Processing

The CFD package provides the data visualisation tools to visualise the results of the flow
problem. This includes – vectors plots, domain geometry and grid display, line and shaded
counter plots, particle tracking etc. Recent facilities are aided with animation for dynamic result
display and they also have data export facilities for further manipulation external to the code.

Variable speed test is carried out to understand the off design operating condition. Computational
Fluid Dynamics simulations are carried out for different speeds 2300 rpm, 2500 rpm and 2880
rpm for the full open and maximum efficiency condition for the impeller and casing designed.
The fluctuating pressure field existing in the volute at variable speeds is studied. The velocity
distribution and fluid flow pattern help in understanding the complex flow phenomenon taking
place inside the pump

Multiple reference frame approach is used for modelling. Selected regions of the domain are
referred to rotating reference frame. The domain is divided into stationary and rotating sub
domains as shown in illustration Rotational interaction between reference frames is not
accounted. So flow is considered to be in a steady state. In the interfaces between rotating and
stationary domains, appropriate transformation of velocity vector and velocity gradient are
performed to compute fluxes of mass, momentum, energy and other scalars. Walls contained
within the rotating sub domain interfaces are assumed to be moving with the fluid. Interface
between rotating sub domain and adjacent stationary sub domain must be a surface of revolution
with respect to the axis of rotation of rotating sub domain

3.4 Boundary conditions

Input details for simulation:

Impeller – Rotating 2300 rpm, 2500 rpm and 2880 rpm

Volute – Stationary

All with static reference pressure 1 atmosphere

Boundary Condition:

Inlet Pressure = -31952.47 Pa

Outlet flow rate = 4 lps

The boundary conditions are specified as follows.

• Flow - material – water-liquid

• Motion type - moving reference frame with rotational speed (rad/s)

• Inlet - pressure inlet

• Outlet - velocity inlet (negative value is specified to signify outward flow)

• Wall - stationary wall

The test rig details captured at the suction and delivery end are used as the boundary conditions
for the fluid domain. The suction pressure is measured by the pressure sensor at the suction end
and the flow rate of the fluid at outlet is captured by the turbine type flow meter. These details
are used as the pressure inlet and mass flow outlet at the boundaries of the flow domain. The
validation is done at the casing pressure measurement done by the pressure sensor over the
computational result at four locations

Before solving the problem, the solution parameters have to be set. First the solver controls are
set to the default under relaxation values for pressure, density, momentum and body forces. First
order upwind criteria are maintained to achieve convergence faster.

The solution has to be initialized to eliminate any garbage values. The residual monitors are set,
and the convergence criteria for continuity, x-velocity, y-velocity, z-velocity, k and are set at
third decimal convergence of 0.001.

The grid has to be adapted for attaining faster convergence. Usage of k- viscous model
necessitates two types of adaptation namely boundary adaptation and Y+ /Y* adaptation.
Adaptation increases the number of cells and adapts the cells adjacent to the walls. The problem
is now ready to be iterated and the number of iterations is specified and the reporting interval is
set as one so as to monitor the trend every time. The iteration continues till the convergence
criteria in all the six parameters namely continuity, x, y, z velocity, k and are attained. The plot
of the convergence can be viewed simultaneously by activating the display window.

The output of the solution can be viewed as projected areas, surface integrals etc. For better
understanding, area-weighted average of parameters like pressure and velocity are taken.

The mass flow rate and volume flow rate can also be obtained. The whole results can also be
viewed graphically in the graphic display window. The display can be in the mode of contours or
vectors. The display will be self explanatory as different ranges of pressure and velocity will
support a different color. Mesh adoption is carried out in the fluent solver. It adapts the mesh
according to the flux parameter. Boundary adaptation technique is utilized in this analysis.
Adaptation increases the number of cells and adapts the cells adjacent to the walls. It is adapted
in the solver automatically and the results are obtained for the adapted condition.
Chapter 4

Results and discussion

4.1 Simulation Results
The results of the flow analysis can be viewed using plots or through surface integrals as shown
in Figures 4.1 to 4.6. Surface integrals provides the required value at the given boundary
condition. Plots give a graphical view of the results and they are of two types, namely, contour
and vector plots. Contour plots show the constant magnitude for a selected variable (isotherms,
isobars etc.). Vector plot is used to give the direction in which the flow occurs.

From Figures, it is inferred that there is a uniform distribution of pressure and velocity around
the impeller in the volute casing for the maximum efficiency condition over the full open
condition. The difference in the flow pattern is the cause of the radial and axial imbalances.rom,
it is inferred that a highly non-uniform distribution of pressure is observed around the impeller in
the volute casing, but it is less when compared to that of 2300 rpm. As a result, the impeller is
subjected to some static radial thrust.
Sample Material Angle No. of blade
code
L1 Cast iron 30 4
L2 Cast iron 45 5
L3 Cast iron 60 6
L4 SS 30 5
L5 SS 45 6
L6 SS 60 4
L7 Aluminium 30 6
L8 Aluminium 45 4
L9 Aluminium 60 5

Level 1 Level 2 Level 3

Stainless steel
Material Cast iron Aluminum

Inlet angle
30 45 60
No. of blade
4 5 6
4.2ANSYS INTRODUCTION
This analysis was performed to test the accuracy of the membrane element results,
because in the case of complex membrane structures there is no reliable analytical
estimate. The idea is to establish the accuracy of the truss model for at membranes, so
that it can be used to produce independent estimates, later on.

4.3Design modular

Computational Aided design (CAE) approach is the effective method of solving non-
linear differential equations that governs static, thermal condition and heat transfer. In
this study, CAE static was used to solve the stress inside the centrifugal Propeller Blade.
Moving Reference Frame (MRF) method is adaptable for the condition where stress
rotates. A separate cell zone has to be mentioned for MRF method, the second cell zone
condition in our study was considered as MRF zone. The assumptions made for this study
are –

1. Static structural 2. Steady state analysis

3. Buckling 4. Modal.

+
 Figure 5: Existing Propeller Blade import to ANSYS

L1 L2

L4
L3

L5 L6

L7 L8

L9

Figure 4: 3D model using L9

orthogonal array condition

No of Max stress (MPa) S/N ratio for

Sample blade s stress
No. Material Angle

L1 CI 30 4 98.778 39.893

L2 CI 45 5 124.72 41.919

L3 CI 60 6 160.74 44.122

L4 SS 30 5 124.29 41.889

L5 SS 45 6 158.9 44.022

L6 SS 60 4 98.494 39.868

L7 AL 30 6 157.36 43.938

L8 AL 45 4 98.284 39.846

L9 AL 60 5 124.1 41.875
 Figure 6: Moment

Pressure = 0.15 Mpa

Figure 7: Applied Pressure

Fixed Support

S/N ratio for

No of Max stress (MPa)
Sampl stress
Materia Angle blade
e No.
l s
L1 CI 30 4 98.778 39.893
L2 CI 45 5 124.72 41.919
L3 CI 60 6 160.74 44.122
L4 SS 30 5 124.29 41.889
L5 SS 45 6 158.9 44.022
L6 SS 60 4 98.494 39.868
L7 AL 30 6 157.36 43.938
L8 AL 45 4 98.284 39.846
L9 AL 60 5 124.1 41.875

Figure 8: fixed support

RESULT FOR ANALYSIS

L1

L2
 L3

L4
L5

L6
Figure:9 - L9 Orthogonal Array responses for Stress
 Taguchi method cannot make judgment and determination on effect of individual
parameters on entire process. The Results were analyzed using Taguchi for
identifying the significant factors affecting the performance measures. The
Analysis of Variance (Taguchi) is to investigate the design parameters and to
indicate which parameters are significantly affecting the output parameters. In the
analysis the sum of squares and variance are calculated. An F-test value at 95 %
confidence level is used to decide the significant factors affecting the process.
Larger F- value indicates that the varying the process parameters makes a big
change on the performance. Table 5 shows the optimum combination of the fan
from static analysis.

The static analysis results of mean effects plot for means and for S/N ratio is shown in
Fig. 10. In these results, the number of blades influences the most on static pressure
while the blade angle influences the least. Since the aim is get the maximum stress
value, Larger is better has chosen. Table 4 represents the maximum affecting
parameters from analysis.

Table 5: Analysis of variance (ANOVA) results for the stress

Process Lev
parameter el
Material AL
Outlet Angle 45
No of Blade 4
As the centrifugal pump is used in very wide verity of applications so, it is
quite necessary to measure the various pump performance parameters for the
efficient operation of centrifugal pump, but Experimental studies to determine
different performance parameters in different type of Propeller Blade material are
complex, time consuming and costly. So by using ANSYS and DOE prediction
model it is easy to predict the performance of different Propeller Blade material and
speed up the production
47
Conclusion
 Modelling and simulation of centrifugal pump impeller has done using Solid Works
software.
 After observing the CFD analysis values we can conclude that e-epoxy has the better
performance is given compared to the Aluminium alloy E-glass/Epoxy material is non
metallic component so, the chattering noise will be low compared to other materials
during the functioning process.
 For manufacturing the centrifugal pump impeller we can proceed with Epoxy/E-glass
material because it has high performance and ot will give good efficient capa and
reasonable manufacturing cost

48
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