DYNAMIC ANALYSIS OF CENTRIFUGAL

PUMP IMPELLER BY FINITE ELEMENT

ANALYSIS

PROJECT REPORT

Submitted by

KARTHIKRAJA.M (813518402002)

in partial fulfillment for the award of the degree of

MASTER OF ENGINEERING IN
CAD/CAM

ROEVER ENGINEERING COLLEGE, PERAMBALUR

DEPARTMENT OF MECHANICAL ENGINEERING
ANNA UNIVERSITY: CHENNAI
SEPTEMBER - 2020
 ANNA UNIVERSITY: CHENNAI

BONAFIDE CERTIFICATE

Certified that this project title “DYNAMIC ANALYSIS OF

CENTRIFUGAL PUMP IMPELLER BY FINITE ELEMENT ANALYSIS”
is the bonafide work of “KARTHIKRAJA.M (813518402002)” who carried
out the work under my supervision. certified further that to the best of my
knowledge the work reported herein dose not from part of any other thesis or
dissertation on the basis of which a degree or award was conferred on an earlier
occasion on this or any other candidate.

SIGNATURE SIGNATURE

Dr. S.SELVAKUMAR, M.E., Ph.D., Prof. M.ANNADURAI, M.E.,

HEAD OF THE DEPARTMENT SUPERVISOR

Professor, Assistant Professor,

Mechanical Engineering, Mechanical Engineering,

Roever Engineering College, Roever Engineering College,

Perambalur - 621 220. Perambalur - 621 220.

Submitted for the university viva - voce examination held on _ _ _ _ _ _ _ _

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

The success of the project work depends upon team work and co-
operation of many people. We would like to take this opportunity to express our
gratitude to the people who supported and guidance made this project a
successful one.
First of all, we take immense pleasure in thanking our respected Chairman
Dr. K.VARADHARAAJEN, B.A., B.L., and respected Vice Chairman
Mr. JOHN ASHOK VARADHARAJAN for providing us this golden

opportunity.

We would like to express our sincere thanks to our principal

Dr.B.GANESHBABU, M.E., Ph.D., for his encouragement and blessings.
We would like to express our sincere gratitude to our vice Principal
Dr.M.PERIYASAMY, M.E., Ph.D, for his guiding and motivation.
We would like to express our stain less gratitude and heartfelt thanks to
our Head of the Department Dr. S.SELVAKUMAR, M.E., Ph.D., for giving
valuable ideas and guiding us to do the good works at right time.
We also thank for our project coordinator Prof. M.ANNADURAI, M.E.,
for his sincere coordination.
We also thank our project guide Prof. R.ARIVAZHAGAN, M.E., for
his sincere guidance.
Last but not least, we would like to convey our special thanks to the
faculty members of Mechanical Engineering department and non-teaching staff
for their help in the project work.
Above all we express our deep gratitude to the almighty who guides and
help us in all works.
ABSTRACT

In this paper we have discus about different impeller materials and their
pressure distribution. The analysis of centrifugal pump impeller design is carried
out using ANSYS. In general, the Efficiency of a centrifugal pump(ηₒ)
=Mechanical efficiency (ηm) ×Volumetric efficiency (ηᵥ). Most of the study has
been done in the improvement of volumetric efficiency but overall efficiency
depends on both factors Hydraulic and Mechanical. Mechanical components- for
Instance, impeller weight and structure produce a mechanical loss. This reduces the
power transferred from the motor shaft to the pump or fan impeller. Also, the
strength of the pump reduces due to stress corrosion problems in impeller which
can be minimized using different material such as Stainless steel and Aluminum.
The modeling of the impeller will be done by using solid works. The analysis of
different impeller

material is done by using Fluid Flow Simulation, it is used to produce good

and optimal result of the impeller materials which can be used for comparing those
materials, analysis has been done by using ANSYS. After getting safe result from
the analysis, the materials will be tested on UTM.

Keywords: Centrifugal Pump Impeller, Static Analysis, Material optimization

 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE.NO.

ABSTRACT iv

LIST OF TABLES vi

LIST OF FIGURES vii

LIST OF GRAPHS ix

LIST OF ACRONYMS x

1 INTRODUCTION 1

1.1 Impeller 3

1.2 Need for the impeller 4

2 REVIEW OF LITERATURE 5

3 PROBLEM IDENTIFICATION 7

3.1 Corrosion 7

3.2 Abrasion Wear 8

3.3 Abrasion-Corrosion 9

3.4 Cavitation-Abrasion-Corrosion 9
4 PROPOSED METHODOLOGY 11

4.1 Impeller-3D Geometry Model and Flow Analysis 11

4.2 Material Properties 15

4.3 Design and Analysis 20

5 PERFORMANCE OF ANALYSIS 25

5.1 Finite Element Analysis 30

5.2 Finite Element Analysis of Impeller 32

5.4 Stress Vs Strain Relation for Al and SS 34

6 RESULT 42

7 CONCLUSION 43

REFERERANCE 44
 LIST OF FIGURES

FIGURES NO TITLE PAGE NO

1 Impeller 2

2 Closed Impeller 12

3 Vane Profit-Circular arc method 24

4 Vane profit- point by point method 25

5 Casing sketch 27

6 Casing solid model 28

7 Impeller modelling 29

8 Meshing impeller 30

9 Casing impeller assembly 32

10 FEA Model 34

11 Meshing model34

12 Von-mises stress for pump impeller (AL) 36

13 Displacement result for pump impeller 36

14 Von-mises stress for pump impeller (SS) 37

15 Displacement result for pump impeller 37

 LIST OF GRAPH

GRAPH NO TITLE PAGE NO

3.1 Flow and Blade Angle 11

3.2 Impeller Blade Loading 11

3.2 Stress Vs Strain Relation 37

LIST OF ACRONYMS

Q.m3/S Volume flow rate

H, m Head

N, rpm Speed

ᵠ, rps Angular velocity

PT, Pa Total pressure

P Fluid density

K Turbulence energy

E Dissipation rate of turbulence energy

1. Introduction

A pump is a mechanical device for moving a fluid from a lower to higher

location, or from a lower to a higher pressure area. Mechanical energy will be
given to the pump and it later converted into hydraulic energy of fluid. Pumps
produce negative pressure at the pressure at the inlet so that the atmospheric
pressure pushes the fluid towards the pump. The fluid coming into the pump is
pushed towards the outlet mechanically where positive pressure is generated.

Pumps are classified in number of the ways based on their purpose,

specifications, design, environment etc. The fluid enters the pump impeller along
or near to the rotating axis and is accelerated by the impeller, flowing radially
outward or axially into a diffuser or volute chamber, from where it exits into the
downstream piping system. Centrifugal pumps are typically used for large
discharge through smaller heads.

A centrifugal pump, the most common type of pumps, has been used in
industrial areas, such as water, sewage, drainage, and the chemical industry
Accordingly, numerous studies have been performed for the designs of various
models of centrifugal pumps. Due to the needs of the industry, optimization using
mechanical concepts has recently been studied in order to make higher-efficiency
pumps with higher heads Centrifugal pumps are very well-known equipment used
in residence, agriculture and industrial applications. It is necessary for a pump
manufactured at low cost and consuming less power with high efficiency. It is the
most used pump in the world. The centrifugal pumps are well described, tested and
robust and also inexpensive to manufacture.

A centrifugal pump 1s a dynamic device. Fluid pressure increases from pump inlet
to the pump outlet when the pump is working. In the centrifugal pump pressure
increases on the fluid by receiving mechanical energy from the motor to the fluid
with the help of rotating the centrifugal impeller. The fluid flows from the inlet to
the center of the impeller and goes out along the impeller blades. The centrifugal
force on the fluid increases the velocity of the fluid.

As the kinetic energy 1s converted to pressure/ hydraulic energy, stress generates

in the impeller, therefore necessary to do an analysis of the impeller strength which
depends on the material used for the impeller. Also, the strength of the pump
reduces due to stress corrosion problems in impeller which can be minimized using
an alternate material having same/more strength.

Computational fluid dynamics (CFD) analysis is being increasingly applied

in the design of centrifugal pumps. With the aid of the CFD approach, the complex
internal flows in water pump impellers, which are not fully understood, can be well
predicted, to speed up the pump design procedure. Thus, CFD is any important tool
for pump designers. The use of CFD tools in turbo machinery industry 1s quite
common today. Recent advances in computing power, together with powerful
graphics and interactive 3D manipulation of models have made the process of
creating a CFD model and analyzing results much less labor intensive, reducing
time and, cost. As a result of these factors, Computational Fluid Dynamics is now
an established industrial design tool, helping to reduce design time scales and
improve processes throughout the engineering world.
FLUID FLOW IN A CENTRIFUGAL PUMP

Fig.1 Impeller

1.1IMPELLER

The impeller is the main rotating part that provides the centrifugal
acceleration to the fluid. They are often classified in many ways. Based on major
direction of flow in reference to the axis of rotation

1. Radial flow

2. Axial flow

3. Mixed flow
Based on suction type

1.Single-suction: Liquid inlet on one side.

2. Double-suction: Liquid inlet to the impelle3. Symmetrically from both sides.

Based on mechanical construction

1. Closed: Shroud or sidewall enclosing the vanes.

2. Open: No shrouds or wall to enclose the vanes

3. Open impeller Enclosed impeller

4. Semi-open impeller

2. Literature Survey

[1]V. Jose Ananth Vino, “Analysis of Impeller of Centrifugal Pump”, International

Journal of Biotech Trends and Technology, Volume 2 issue Number-Jan 2012

In general, the Efficiency of a centrifugal pump = Mechanical efficiency×

Volumetric efficiency (y). Most of the study has been done in the improvement of
Hydraulic efficiency but overall efficiency depends on both factors 1ydraulic and
Mechanical. Mechanical components for example, impeller weight and structure
produce a mechanical loss that reduces the power transferred from the motor shat
to this pump or fan impeller. Also, the strength of the pump reduces due to stress
corrosion problems in impeller which can be minimized using an alternate material
having same/more strength. The modelling& of the impeller will be done by using
solid model ling software, CATIA. The meshing and boundary condition
application will be carried using Hyper mesh, it is also used to produce good and
optimal meshing of the impeller to obtain accurate results and analysis has been
done by using ANSYS. A static analysis on 3HP pump impeller has been carried
out to examine the stresses and displacements of the centrifugal impeller.
Conventional MS material is replaced with glass fiber composite material. After
getting safe results from the analysis, the model will be fabricated and testing will
be done on UTM.

[2 ] A Syam Prasad, BVVV LakshmipathiRao, A Babji, Dr. P Kumar Babu, Static

and Dynamic Analysis of a Centrifugal pump Impeller, International Journal of
Scientific& Engineering Research, Volume 4, issue 10, October-2013
ISSN 2229- 5518 comparison of computational results for various types of pumps
showed good agreement for the twisted-blade pumps. However, for the straight-
blade pump, the computational results were somewhat different from widely
published ex- per mental results. it was found that the predicted results relating to
twisted-blade pumps were better than that re- lathing to the straight-blade pump,
which suggests that the efficiency of a twisted-blade pump will be greater than that
of a straight-blade pump. The calculation also predicts reasonable results in both
the flow pattern and the pressure distribution

[3] E.C. Bacharoudis, Parametric Study of a Centrifugal Pump Impeller by

Varying the Outlet Blade Angle The pump design is facilitated by the development
of computational fluid dynamics and the complex internal flows in water pump
impellers can be well predicted. Various parameters affect the pump performance
and energy consumption. The impeller outlet diameter, the blade angle and the
blade number are the most critical. The present paper describes the simulation of
the flow into the impeller of a laboratory pump in a parametric manner. 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 and a successful correlation of local and global parameters. the
numerical solution of the discretized three-dimensional, incompressible Navier-
Stokes equations over an unstructured grid is accomplished with a commercial
CFD finite-volume code. For each impeller, the flow pattern and the pressure
distribution in the blade passages are calculated and finally the head-capacity
curves are compared and discussed.

[4] Kay Thi Myaing, Design and Analysis of Impeller for Centrifugal Blower using
Solid Works.

In this paper, backward-curved impeller was simulated and compared with

theoretical result by using SolidWorks Software. Flow Analysis is also based on
the computational fluid dynamic and can obtain the results for the estimation of the
outlet flow velocity components, pressure distribution and temperature distribution
for impeller. SolidWorks is used to build 3D geometry for analysis using
SolidWorks Flow Simulation. The impeller design calculation consists of shaft
diameter, hub diameter, vane inlet diameter, and inlet width, inlet vane angle,
outside diameter and outlet width. The inlet and outlet velocities are considered.
The impeller inlet width and outlet width are designed 43 mm and 22 mm. Impeller
inlet vane angle is calculated 34° and outlet vane angle is 50°. Impeller inlet
diameter and outlet diameter are 260 mm and 600mm. The number of vane is 12.
Centrifugal blower is very useful in many industries and farm machinery
operations because this one is very simple and easiest way to support air supply for
these applications.

3. Problem Identification

As the present centrifugal pump impeller is made up of material MS, the

weight of the impeller is high because of material density. As the kinetic energy is
converted to pressure hydraulic energy, stress generates in the impeller, therefore,
it 1s necessary to do an analysis of the impeller strength which depends on the
material used for the impeller. Also, the strength of the pump reduces due to stress
corrosion problems in impeller which can be minimized using an alternate material
having same/more strength.

Due to following conditions, mechanical efficiency reduces and power

requirement of the pump increases.

3.1. Corrosion

Corrosion is the destructive attack of a metal by chemical or electrochemical

reaction with its environment. Corrosion by itself is usually not a difficult problem;
in fact, many materials are available to handle most fluids. It is, however,
important to understand the various types of corrosion and factors affecting the
corrosion rate in order to select the appropriate materials. It can be quite difficult to
choose a material to withstand multiple factors, such as corrosion in addition to
erosion and/or cavitation.
 A general rule of thumb is to first select materials that will withstand
corrosion and then select the one with the most appropriate abrasion and/or
cavitation resistance. Further, the corrosive properties of the liquid may vary with
one or more of the following liquid conditions: temperature, concentration, purity,
velocity, suction pressure, entrained air, and entrained solids.

3.2 Abrasive wear

Abrasive wear 1s the mechanical removal of metal from the cutting or

abrading action of sods carried in suspension in the pumped liquid. The rate of
wear for any material is dependent upon the following characteristics of the

suspended solids:

1. Solid concentration

2. Solids Size and mass

3. Solids shape (spherical, angular or sharp fractured surfaces)

4.Solids hardness

5. Relative velocity between solids and metal surface.

The rate of wear is also dependent upon the materials selected for the
rotation and stationary components of a centrifugal pump. Although metal
hardness is not the sole criterion of resistance to abrasive wear, hardness does
provide a convenient index in selecting ductile materials usually available for
centrifugal pumps. Such an index 1S shown in Figure 1, where the abrasive wear
resistance ratio is shown as a function of Brinell hardness for various materials. It
should be noted that a brittle material, such as cast iron, exhibits a much lower
ratio than either the steels or bronzes of the same hardness. The following
tabulation can also be used as a guide in material selection, listed in order of

increasing abrasive-wear resistance:

1. Cast iron

2. Bronze

3. Manganese bronze

4. Nickel-aluminum bronze

5. Cast steel

6. 300-series stainless steel

7. 400-series stainless steel

3.3. Abrasion-Corrosion

The corrosion rale of most metals and alloys in any liquid environment
under static conditions depends upon the resistance of the film that forms on the
Surface and protects the base metal from further attack.

Damage to or removal of his film by abrasion exposes the unprotected base

metal to the corrosive environment, and metal removal continues unabated. When
the liquid pumped is corrosive and also contains abrasive solids, higher alloyed
materials (Such as Stainless steel) are often required to achieve acceptable pump
lite. The use of Such alloy's 1s more 1portant when a pump 1s operated only
intermittently and not flushed after each pumping cycle

In centrifugal pumps, the impeller is particularly susceptible to abrasion-

corrosion. Although the casing can be damaged by this, the problem 1s usually
secondary to that of the impeller. The diffuser-type casing with its many vanes 1s
more susceptible to abrasion-corrosion than is the volute-type casing with only one
vane - the casing tongue - as an obstruction to the line of flow.

Wearing rings arc also susceptible to abrasion-corrosion and should receive

special consideration in material selection. The higher fluid velocities through the
small clearance annulus can result in a high rate of wear, unless the proper material
is selected.

3.4. Cavitation-Abrasion-Corrosion

Cavitation erosion (which can normally occur with high-suction energy

pumps) 1s the removal of metal as a result of high, localized stresses produced in
the metal surface Iron the collapse (implosion) of cavitation vapor bubbles in
higher pressure regions of the impeller inlet. In an abrasive-cavitation and
corrosive environment, the rate of damage is further accelerated and can occur
even in Low-Suction energy pumps. The base material is eroded away as the
abrasive particles are accelerated towards the impeller surface (by the implosive
force of the capitation bubbles), which continuously removes the corrosion
products so metal removal proceeds unabated.

Other factors affecting material selection include:

1.Type of pump
2. Initial cost

3. Economic lite

4. Ambient conditions-temperature and environment

5. Containment integrity for hazardous materials

6. Size of pump

7. Intermittent or continuous duty

8. Pump suction energy level required

Method of manufacturing a company specializes in the following criteria should be

considered in the selection of the material for a centrifugal pump impeller

1. Corrosion resistance
2. abrasive-wear resistance
3. Cavitation resistance
4. Strength (primarily for the casings)
5. Casting and machining properties
6. Cost

Problem Identified from existing pump:

1. Non-optimized size of the impeller

2. Weight of the pump impeller
3. Impeller axial forces acting on side walls and internal blades
4. Water head and pressure acting on impeller profile
4. Proposed Methodology

4.1. Impeller 3D geometry model and flow analysis

The 3D impeller geometric model was created in the CCAD code

6yinputting the number of blades, the definition of the hub and shroud contours,
and the associated hub and shroud blade normal thickness and wraps angle
distributions. Appropriate curve fitting procedures (in CCAD) we employed to
represent the hub and shroud contours and thickness distributions and to deduce
the hub and shroud blade angle distributions.

Geometry and fluid dynamics features available in CCAD were used to

analyze impeller a property, Such as the meridional channel and the blade passage
areas, as well as blade loading viscid flow analysis was performed to derive
information on blade loading for the existing 1mpeller. Figure 2 shows the blade
and flow angles along the hub and shroud contours, the differences between the
two at the leading edge and the trailing edge giving the flow incidence and
deviation angles, respectively. They agree well with the 1D analysis results, given
in the table 1, and they confirm the large hub inlet incidence angle. Slade loading
distributions, based on the velocity difference between the blade pressure and
suction Side at each computing station, are presented in Figure 3. The high
incidence angle at the hub impeller inlet is reflected by the high blade loading
downstream of the leading edge. The distribution of the blade loading in the rear
60% of the blade is mostly uniform and remains below the 0.6 blade loading level
imit. The peak of the blade loading in the shroud/TE region results from the
prohibitive curvature of the shroud contour for this Q3D computation. Figure
displays the relative velocity distributions along the hub and shroud contours with
the effect of the high shroud curvature near the impeller exit clearly indicated.
Step analysis

Design of CAD Model of Components

Analysis of the existing Component

Study of stress plot and displacement

Study of alternative materials

Analysis of the component using alternative materials

Study of analysis result

For the reference, we are using Kirloaskar pump of following specifications Head
H= 13m, Discharge Q-515LPM or 0.00858 m3/sec

HP motor 2800 rpm

 Table.4.1 Dimension of a pump impeller

D outer=216mm
D shaft=16 mm
D hub=20mm
D eye=107.6mm
Width =13mm
No. of blades=8 no’s
Width of blade=125.mm
B1=26.89 degree
B2=19.29 degree

CAD model is prepared by doing design calculations based on given specifications

and using Solid works CAD software. Computational fluid dynamics of fluid
mechanics was used for numerical analysis and data structures to solve and analyze
problems that involved material selection.

fig 2. impeller types

4.2. Material Properties

Mechanical properties of materials are those related to its ability to

withstand external mechanical forces such as tensile forces, compression forces,
twisting, bending, and sudden impact.

Stainless Steel

Stainless steels are notable for their corrosion-resistance, which Increases

with increasing chromium content. Molybdenum additions increase corrosion
resistance in reducing acids and against pitting attack in chloride solutions. hub,
there are numerous grades of stainless steel with varying chromium and
molybdenum contents to suit the environment the alloy must endure. Thus stainless
steels are used where both the strength of steel and corrosion resistance are
required.

Table 4.2 General Properties of SS

S. No Type Corrosion Hardness Magnetism Harden Weld

Resistanc able ability
e With
thermal
treatments
1 Martensitic Low High Yes yes Poor
2 Ferritic Good Medium- Yes No Limited
low
3 Austenitic Excellent High No No Excellent
4 Duplex excellent High Yes No Good
s.no Mechanical Carbon Alloy Stainless Tool steel
Properties steel steel steel

1 Density 7.85 7.85 7.75-8.1 7.72-8.0

(1000 kg/m3)
2 Modulus of 190-210 190-210 190-210 199-210
elasticity
(G Pa)
3 Poisson’s 0.27-0.3 0.27-0.3 0.27-0.3 0.27-0.3
Ratio

4 Tensile 276-1882 758-1882 515-827 640-2000

strength(MPa)
5 Yield 186-758 366-1793 207-552 380-440
strength(MPa)
6 Elongation 10-32 4-31 12-40 5-25
percentage
7 Brinell 86-388 149-627 137-595 210-620
hardness no.
(3000kg)

Common types of stainless steel used in impellers:

There are a wide variety of compositions of stainless steels possible,

determined by the properties desired to best fit the application. The most common
grades of stainless steel used in impellers are listed in the table below.

Table.4.3 Common Type of SS

Types of key Components in Corrosion resistance Application
stainless steel alloy
303 Chromium-18% Slightly lower than Suitable for objects
Nickel-8% 304 requiring
Phosphorous sulphur machining
304 Chromium-18%..min Widely used.
Nickel 8% …min Good resistance to Popular
Carbon 0.08%…max Oxidizing acids, For dairy, food&
food Widely used. beverage, textile,
Popular chemical,
mineral and
photochemical
processes.
316 Chromium-16%..min Greater corrosion Can handle harsher
Nickel 10% …min resistance than 304. conditions than
Carbon 0.08%…max Resistance to pitting 304.popular for
Molybdenum 2-3% by chlorides or inks, paper, pulp,
brines hypochlorite textiles, bleaches,
solutions(bleach), rubbers,
and other industrial petrochemical,
chemicals and Pharmaceuticals,
solvents . and chemical
process.

316L Chromium-16%..min L indicates low Suitable for any

Nickel 10% …min carbon content. 316 application
 Carbon 0.03%…max Same corrosion For impellers with
Molybdenum 2-3% resistance as 316, blades welded to
plus of sensitization. shaft
316Ti Chromium-16%..min Similar to lower Suitable for any
carbon 316L.the 316 application for
Nickel 10% …min
titanium prevents most conditions,
Carbon 0.08%…max sensitization, and the 316L and 316
includes the same Ti are
titanium 2-3%
corrosion resistance interchangeable.
as 316, advantage noted
for 316 Ti in
environments over
600 degree Celsius

Aluminum alloy 6061

Aluminum is remarkable for its low density and its ability to resist corrosion
through the phenomenon of passivation. Aluminum and its alloys are vital to the
aerospace industry and important in transportation and building industries, such as
building facades and window frames. the oxides and sulfates are the most useful
compounds of aluminum.
Table 4.4 Compounds of Aluminium Alloy

Elements(%) Alloy 6061 Alloy *65032

Mg 0.80-1.20 0.07-1.20
Si 0.40-0.80 0.40-0.80
Cu 0.15-0.40 0.15-0.40
Cr 0.04-0.35 0.15-0.40
Mn 0.15(max) 0.15-0.35
Fe 0.70(max) 0.70(max)
Zn 0.25(max) 0.20 (max)
Ti 0.15(max) 0.20 (max)
Others 0.05(max) each 0.05 (max) each
0.05 (max) total 0.05 (max) total
Remainders aluminium Aluminium

In alloy 656032, either “Mn” or “Cr” shell be present.

4.5 Properties of aluminum alloy

Property AL 6061-T6
Electrical conductivity 0.0251
Mass density 0.0027
Young’s modulus 68.90
Poisson’s ratio 0.33
Specific heat capacity 0.89
Thermal conductivity 167
 Aluminum alloy 6061 is a precipitation-hardened aluminum alloy containing
magnesium and silicon as its major alloying elements, Originally called "Alloy
61S", it was developed in 1935, It has good mechanical properties, exhibits good
weld ability, and is very commonly extruded (second in popularity only to 6063). It
is one of the most common alloys of aluminum for general-purpose use.

4.3. Design and analysis

Impeller design

The impeller was designed for the operational condition of

head (H)=24m: flow rate (Q)= 1.58m3/sec; and speed (N) 2880rpm.

The mixed flow impeller will be analyzed for multi-phase flow (oil and water)
Circular arc method

The impeller is arbitrarily divided into a number of concentric rings between

r1 and r2. The radius of arc p. between any two rings r band raise obtained from
the equation. The computations of the values of p for various rings and the radii of
arc of the vane are shown in fig5.

Fig.3. Vane profile-Circular arc method

Point by point method

The co-ordinates for developing the vane profile together with the inlet and
outlet angle depends on the radius (r). tabular integration method is used for
obtaining the co- ordinates. The radiuses with respect to angle are obtaining from
below equation.

The values of the profile co-ordinates and the vane profile are shown in fig.6.

Fig.4. vane profile-point by point method

Geometric Modelling

Solid modeling (or modeling) is done using consistent set of principle tor
mathematical and computer modeling of three-dimensional solids. Solid modeling
Is related areas of geometric modeling and computer graphics by its emphasis on
physical fidelity. Together, the principles of geometric and solid modeling form the
foundation of computer-aided design and in general support the creation,
exchange, visualization, animation, interrogation, and annotation of digital models
of physical objects

Modeling was done using Solid works CAD software

Modeling and meshing

The first step in CFD simulation is preprocessing. In preprocessing

modeling and mesh is generated. The CAD model and mesh was carried out using
octree- based mesh technology, combined with a unique immersed boundary
approach embedded with mesh from technical paper. Two –scale wall function
approach automatic detection of initial mesh settings resolves the governing
equations. Automatic meshing tools allowed creating mesh for any arbitrary 3D
model. Meshing subdivides the model and the fluid volume into several tiny pieces
called cells. The multi block multi grid approach (structured mesh) was used to
approximate the solid fluid boundary.

Flow simulation using CFD

CFD approach was carried out to analyze the behavior of flow field in the
impeller using the SWFS soft- ware. SWES software is a powerful CFD tool that
enables designers to quickly and easily simulate fluid flow for the success of
designs. Design cycles are expensive and time-consuming.
 CFD analysis is able to help the designers to optimize the designs by
simulating several concepts and scenarios to make absolute assessment. SWFS
solves time-dependent three-dimensional Reynolds-averaged Navier-Stokes
equations using the k-E turbulence model with the Finite Volume Method (FVM)
Technical paper

Boundary condition

The fluid is permitted to arrive at the impeller eye which turns the flow
centrifugally outwards through the blades. The boundary conditions for the
impeller are inlet, outlet, and impeller rotation. The inlet volume flow at the
entrance of the impeller was given as inlet, the outlet was set as static pressure
equal to the environmental pressure; and relative velocity of the impeller was set as
global rotating frame as shown in Fig. 4. Since the working fluid is water, the
simulations were performed based on the assumptions: incompressible flow, no-
slip boundary conditions have been imposed over the impeller vanes and walls, and
gravity effects are negligible.

5. Performance of Analysis

Casing and Impeller Modeling

Three-dimensional model of an impeller was first created in Solid works

2014 software and exported into IGES files. The IGES files were then imported
into fluid flow simulation, the mesh generator. The fluid volume was split into a
rotating fluid volume, a scroll volume, an inlet cone volume, and an inlet/outlet
duct volume. The inlet and outlet ducts were intentionally set to simulate the actual
measuring situation and to provide better boundary conditions for simulations. The
flow was assumed fully developed when leaving the inlet and outlet ducts.
 The impeller wheel volume was defined as a rotating reference frame with
constant speed, and other blocks were defined in a stationary frame.

Fig.6 casing solid model

 Fig.7. Impeller modeling

Meshing

The first step in CFD simulation is preprocessing. In preprocessing

modeling and mesh is generated. The CAD model and mesh was carried out using
Octree based mesh technology, combined with a unique immersed boundary
approach embedded with mesh from Technical paper. Two-Scale Wall Functions
approach automatic mesh generation with automatic detection of initial mesh
settings resolves the governing equations.

Automatic meshing tools allowed creating mesh for any arbitrary 3D model.
Meshing subdivides the model and the fluid volume into several tiny pieces called
cells. The multi block multi grid approach (structured mesh) was used to
approximate the solid fluid boundary
 Fig.8 meshed Impeller

Assembly Modeling

The design evolution is involved for assembly modeling. 3D parts and

assembly modeling is done in CAD through which the design intent of a part or
assembly was accurately and unambiguously described by a 3D virtual model, for
almost tangible representation of physical reality.

Creating assembly structure

Using joints to position components

Simulating motion in assemblies

 Fig.9.casing and impeller assembly

5.1. Finite Element Model

Finite Element analysis tool offers the tremendous advantages of enabling

design teams to consider virtually any modelling option without incurring the
expense associated with manufacturing and machine time. The ability to try new
designs or concepts on the computer gives the opportunity to eliminate problems
before beginning production. Additionally, designers can quickly and easily
determine the sensitivity of specific modelling parameters on the quality and
production of final parts. The similar aluminum plates, and the various tool
geometries model is created by modelling software like ANSYS and it is imported
in to the analysis software and loading, boundary conditions are given to the
imported model and result are evaluated by post processor

Fatigue life can be over the whole model of scoped just like any other contour
result in workbench (i.e. parts, surfaces, edges, and vertices). In addition, this and
any contour result may be exported to a tab-delimited text file by a right mouse
button click on the result. This result contour plot shows the available life for the
given fatigue analysis. If loading is of constant amplitude, this represents the
number of cycles until the part will fail due to fatigue. n a Stress Life analysis with
constant amplitude, if the equivalent alternating stress is lower than the lowest
alternating stress defined in the S-N curve, the life at that point will be used.

Factor Fatigue Safety Factor is a contour plot of the factor of safety with respect to
a fatigue failure at a given design life. The maximum Factor of Safety displayed is
15. Like damage and life, this result may be scoped. For Fatigue Safety Factor,
values less than one indicate failure before the design life is reached.

Fig.10. FEA Model

Finite Element Analysis of impeller

The meshing and boundary conditions are applied for pump 1mpeller CAD
model by using Hyper mesh. After completing the meshing and detinin8 the
boundary conditions the static structural analysis is done by using ANSYS RI5.0
FEA software for the different materials. The analysis 1s done 1or the material SS
and Aluminum Alloy respectively, in order to check Equivalent Stresses and its
corresponding deformations induced in each material. The 3D CAD model of 3HP
pump impeller is imported in Hyper mesh and the surface was created and meshed.
Here we are using 3D elements called as tetrahedral elements for meshing as all
the dimensions of the pump impeller are measurable.

No. of Nodes No. of Elements Element Size Types of Meshing

9638 28716 2mm Tetrahedral

Fig. 12. Meshed Impeller

At first the numerical model is applied to calculate the flow field developed in the
standard design impeller, for various load conditions and for a constant rotation
speed of 1500 rpm. The 'nominal volume flow rate is taken 31 m3 /h to comply
with the corresponding laboratory model pump design point. Fig. the resulting
contours of pressure and the velocity vectors at two grid levels that cross the
impeller normal to- and through its axis of rotation. Increased flow velocity can be
observed at the blade inlet due to the blockage of the flow, whereas on the contrary
the pressure is reduced. Further downstream the contours become smooth between
the blades and the pressure increases continuously towards the exit of the
computational domain.

The minimum pressure appears, as expected, at the suction side and

near the leading edge of the blade. The flow seems to enter almost parallel to the
blade and the streamlines follow a regular pathway between the blades, except of
the upper section near the shroud, where some recirculation can be observed. Fig.
below illustrates the corresponding flow field for a much reduced flow rate, equal
to 20% of the 'nominal. The different flow characteristics can be clearly observed:
The pressure gradients are lower throughout the domain and the minimum values
are higher. However, a strong recirculation is established within almost the entire
blade-to-blade region which, according to the theory, rotates in the reverse
direction than the impeller.
Stress analysis

Result for Aluminium alloy

fig.13 von- mises stress for pump impeller

fig.14. displacement result for pump impeller

Result for stainless steel

fig.15 von- mises stress for pump impeller

fig.16. displacement result for pump impeller

Table 5.1 Displacement comparison of AL and SS

S.NO Material Max. stress Max. Weight

displacement
1 steel 1.27 M Pa 0.0011mm 3.09
2 Aluminum 1.40 M Pa 0.0035mm 1.06
Alloy 6063

The steel impeller was having 1.37 MPa of maximum stress and maximum
displacement was 0.0011mm. the weight of impeller was 3.09.

The aluminum impeller was having 1.40 M Pa of maximum stress and

maximum displacement was 0.0035mm. the weight of impeller was 1.06.

It is observed from the finite element analysis results that the stresses are
maximum at the shaft location. It is also observed that all the materials have stress
values less than their respective permissible stress values. From the comparison of
FEA results, it is observed that SS is the material which is having the less weight,
good strength and non-corrosive properties it is best suited alternate material for
pump impeller and 1s expected to perform better with a satisfying amount of
weight reduction. Also, it is easily available.

As mentioned prev1ously, fatigue material properties are based on

uniaxial stresses but real world stress states are usually multiaxial. This result gives
the user some idea of the stress state over the model and how to interpret the
results. Biaxial indication is defined as the principal stress smaller in magnitude
divided by the larger principal stress with the principal stress nearest Zero ignored.
 A biaxiality of zero corresponds to uniaxial stress, a value of -1 corresponds
to pure shear, and a value of l corresponds to a pure biaxial state. As you can see in
the Biaxiality Figure, the majority of this model 1s under a pure uniaxial stress,
with parts exhibiting both pure shear and nearly pure biaxiality.

When using the biaxiality plot along with the safety factor plot above, it can
be seen that the most damaged point occurs at a point of mOstly uniaxial stress. If
the most damaged spot was under pure shear, then it would be desirable to use S-N
data collected through torsional loading if such data was available. Of course
collecting experimental data under different loading conditions is cost prohibitive
and not often done. Note that for

non proportional fatigue loading, there are multiple stress states and thus
there is no Single stress axially at each node.

Thus if the fatigue tool has non-proportional loading, the user may select
either to view the average or standard devi1ation of stress biaxiality. The average
value may be interpreted as above and in combination with the standard deviation,
the user can get a measure of how the stress state changes at a given location. Thus
a small standard deviation indicates a condition where the loading is proportional
while a larger deviation indicates change in the direction of the principal stress
vectors.
 Stress Vs Strain relation for Al and SS

Stress Vs Strain relation for Al and SS

The analyses were made for the circular arc method and point by point
method with forward and backward curved vanes. The results of the flow field
investigation are presented in terms of velocity and pressure distribution.
6. Result

The main result of this project is to analyses the material properties and
weight optimize the impeller. This was done by replacing conventionally used MS
material with SS material.

For this following result are achieved by

Studied the existing model

Calculated forces and boundary conditions

Carried out meshing and analysis.

Carried out material optimization.

It is observed from the finite element analysis results that the stresses are
maximum at the shaft location. It is also observed that all the materials have stress
values less than their respective permissible stress values. From the comparison of
FEA results, it is observed that SS is the material which is having the less weight,
good strength and non-corrosive properties it is best suited alternate material for
pump impeller and 1s expected to perform better with a satisfying amount of
weight reduction. Also, it is easily available.
7. Conclusion

Numerical investigations were carried out to analyze the flow field in the
pump impeller using ANSYS. To design a centrifugal pump impeller a procedure
is proposed. The design procedure leads to good results in a lesser time. The effect
of the forward curved vane and backward curved vane were analyzed. From the
numerical results the backward curved vanes have better performance than the
forward curved vane. The vane profile was developed by two methods viz. circular
are method and point by point method

It is observed from the finite element analysis results that the stresses are
maximum at the shaft location. It is also observed that all the materials have stress
values less than their respective permissible stress values. From the comparison of
FEA and experimental testing results, it is observed that SS is the material which is
having the less weight, good strength and non-corrosive properties it is best suited
alternate material for pump impeller and is expected to perform better with a
satisfying amount of weight reduction. Also, it is easily available.
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