Advancements and Insights in CFD Analysis of Propeller Fan

Performance: A Comprehensive Literature Review

Sunil Shinde, Omkar Pankey, Kannad Patil, Aditya Patil, Aryan Paparkar, Maitreyee
Panchale

Abstract

This review explores the evolution of CFD and its application to propeller fan
analysis. It delves into the interplay between fan blades and airflow, discussing
the potential for refined designs and enhanced performance. The literature
review synthesizes a range of studies that use CFD methodologies to investigate
propeller fan behaviour, offering a comprehensive overview of progress,
challenges, and insights.

Introduction

In various industrial, commercial, and residential settings, the effective movement of air holds
immense significance. Propeller fans, with their uncomplicated design, compactness, and capacity to
handle high airflow rates, have emerged as pivotal components in systems requiring ventilation,
cooling, and air circulation. To optimize the functionality of these fans and address the escalating
demand for improved efficiency and reduced noise emissions, a profound comprehension of the fluid
dynamics they encompass becomes imperative. This has paved the way for the widespread adoption
of Computational Fluid Dynamics (CFD) as an invaluable tool for analysing and simulating the
intricate flow patterns within propeller fans.

CFD, a numerical technique, has undergone remarkable evolution over recent decades due to its
aptitude for unravelling complex fluid dynamics phenomena. Its application to propeller fan analysis
presents an exceptional opportunity to scrutinize the interplay between fan blades and the surrounding
airflow, resulting in refined designs and enhanced performance. This review of literature endeavours
to explore the extensive spectrum of research that leverages CFD methodologies to delve into the
behaviour of propeller fans. By amalgamating findings from diverse studies, the objective is to offer a
comprehensive panorama of progress, challenges, and insights that have emerged in this domain.

The transformation brought about by CFD has redefined how researchers and engineers approach the
study of fluid dynamics within propeller fans. Traditional experimental methods often carried inherent
limitations, spanning costs, time constraints, and the capacity to capture intricate flow nuances. In
contrast, CFD provides a virtual laboratory, enabling visualization, quantification, and analysis of
intricate flow phenomena with unparalleled precision. The accuracy and efficiency of CFD
simulations have witnessed consistent enhancement, courtesy of advancements in computational
capabilities and numerical algorithms. Consequently, CFD has become an indispensable asset for
propeller fan research and the fine-tuning of design optimizations.

This comprehensive literature review systematically traverses pivotal facets of CFD analysis as
applied to propeller fans. It delves into methodological nuances encompassing numerical simulations,
encompassing the selection of turbulence models, grid generation strategies, and delineation of
boundary conditions. Furthermore, the review accentuates the insights furnished by these simulations,
spanning the characterization of flow dynamics encircling the blades to the determination of
performance metrics encompassing pressure fluctuations, volumetric flow rates, and overall
efficiency.
 In a backdrop where the quest for energy efficiency and ecologically sound solutions acquires
heightened significance, the trajectory of propeller fan technology assumes paramount importance.
CFD analysis holds the potential to exert a transformative influence on this technology, guiding
design refinements through invaluable insights. By parsing the corpus of literature concerning CFD
analysis of propeller fans, this review seeks to contribute to the broader comprehension of fluid
dynamics and fan performance. Simultaneously, it identifies prospective avenues for future research
and innovation within this dynamic and evolving arena.

Literature Review
Sr. Title Objective
No
.
1 COMPUTATION Pradeep Shetty et al. have
AL FLUID utilized numerical methods to
DYNAMICS establish a connection
SIMULATION OF between the mass flow rate of
PROPELLER a propeller-type axial fan by
FAN [1] conducting comprehensive
simulations to analyze the
fan's behaviour.
2 Model and full Takafumi Kawamura et al.
scale CFD analysis performed CFD analysis to
of propeller boss compare PBCF efficiency in
cap fins (PBCF) model and full-scale
[2] scenarios. Validate with data,
explore design parameters,
interactions, and unsteady
effects, and propose
optimized design insights.
Methodology Results
Pradeep Shetty et al. have first Pradeep Shetty et al.
provided a flowchart of the have created a table
process. They then gave a based on their
detailed explanation of each step, findings which
followed by giving the boundary includes pressure,
conditions. flow rate and inlet
velocity. The authors
have then validated
their findings through
an experiment.
Takafumi Kawamura et al. Takafumi Kawamura
provided a study that focuses on et al. have analyzed
reverse and normal Pressure PBCF performance at
Overhaul Tank (POT) model scale as well
experiments and their as full scale
implications. The computations Reynolds number
were performed for two using CFD for
propellers, both at model and hydrodynamic
full-scale Reynolds numbers. enhancement
assessment.

3 CFD Analysis of Andrea Di Mascio et al.
Propeller-Rudder performed in-depth CFD
Interaction [3] analysis to investigate the
intricate hydrodynamic
interaction between propellers
and rudders, aiming to gain
insights into flow patterns,
forces, and efficiency
improvements for optimized
marine propulsion systems.
4 CFD Analysis of This paper by Jie Zhao et al.
Ducted-Fan UAV aims to enhance small ducted-
Based on Magnus fan aircraft control by
Effect [4] introducing a novel actuator
system utilizing the Magnus
effect. The system stabilizes
the aircraft by adjusting
rotary cylinders' speed and
direction, minimizing wing
Andrea Di Mascio et al. have Andrea Di Mascio et
created a mathematical model al. concluded that
based on URANS equation. numerical
The simulations replicate
experimental activity was vortex-body
carried out in the Cavitation interactions, studying
Tunnel at CNR-INSEAN. unsteady rudder
loads, tip vortex
distortion, slipstream
misalignment.
Future: diverse loads,
advanced models
(DES, LES).
Jie Zhao et al. described the CFD analysis done
Magnus effect and conducted by Jie Zhao et al.
CFD analysis around the effect. shows orthogonal
The entire grid computing region alignment of the four
was divided into two flow fields: cylinders in the
inner and outer flow field. ducted-fan UAV
6000rpm. With the wind speed during hover and
increases, the Magnus force forward flight,
increases generating Magnus
 speed disturbances.
5 CFD Analysis of Dushyant Dwivedi et al. ’s
Axial Flow Fans work deals with axial flow
with Skewed fans that are primarily used
Blades [5] for providing the required
airflow for heat and mass
transfer operations in the
various industrial equipment
and processes.
6 CFD Analysis for Chung Chang et al. aim to
Ducted Fans with develop an incompressible
Validation [6] Navier-Stokes solver to
analyze ducted fan flow,
incorporating fan effects
through momentum source
modeling. Validate and
establish CFD program's
utility for axial flow analysis
in fan design.
7 Computational Diego ALMAZO et al. aim to
Fluid Dynamics utilize Reynolds-Averaged
Simulation for Navier-Stokes (RANS) and
Propeller [7] moving grid method for
accurate five-blade propeller
flow resolution under design
and off-design conditions.
Address viscous effects,
boundary layers, wakes, and
unsteady vortices, focusing
on Airfoil 6512 propeller
simulations.
Results & Discussion
1. Flow Patterns:
The propeller fan's inside was found to have intricate flow patterns through CFD study. Air
was propelled toward the fan blades as it was brought in through the intake area and whirled
strikingly and changes linearly. force for control
torque. The Magnus-
based actuator
system enhances
stability by
minimizing wing-
induced disturbances.
The CFD analysis is done by Dushyant Dwivedi et
modelling the axial fan in al. concluded that
GAMBIT 2.2 and using Standard computational
kє model with the Standard wall analysis of axial flow
function for modelling fans with skewed
turbulence. The analysis is blade profiles reveals
carried out with blade stagger rpm-dependent
angle of 25o, Skewed angle of trends in static
8.3o and at 1440 rpm and 1800 pressure, flow rate,
rpm. Various numerical method and efficiency.
are also applied. Computational and
experimental trends
correlate, validating
the study.
Chung Chang et al. used various Chung Chang et al.
mathematical equation including developed Navier-
some governing equations like Stokes flow code
the continuity equation, accurately predicted
momentum equation and hover performance
Newton’s law of viscosity. The for industrial ducted
study also employs FLUENT fan models, showing
CFD software for aerodynamic good agreement with
predictions and flow field wind tunnel data.
analysis. A grid process was also This establishes
used to analysis the flow of code's accuracy for
wind. axial flow analysis in
fan design.
Diego ALMAZO et al. Diego ALMAZO et
employed a Reynolds-Averaged al. came to a result
Navier-Stokes (RANS) method that grid refinement
in conjunction with an reduces errors,
overlapping moving grid ANSYS Fluent
approach to provide accurate models fan efficiency
resolution of a five-blade via pitch angle. Wind
propeller flows under both the tunnel validates
design and off-design conditions. simulations. Optimal
It is well known that some off- 40-degree pitch angle
design propeller flow phenomena improves exit edge
are dominated by viscous effects profiles.
and cannot be accurately
predicted by the potential flow
methods.
 around the blades. The rotational action of the blades caused the airflow to be then discharged
radially outward. Recirculation zones, vortices, and turbulence in specific locations were
signs of flow separation and losses.
2. Pressure Distribution:
Significant variances were visible in the pressure contours throughout the fan assembly. Low-
pressure areas were more common close to the hub area, whereas high-pressure areas were
seen close to the blade tips. Foreseeing the structural integrity of the fan blades and
maximizing the fan's performance require an understanding of pressure distribution.
3. Efficiency:
By examining the fan's power consumption and airflow produced, its effectiveness was
assessed. The entire pressure rise of the fan and its mechanical efficiency were calculated
using CFD models. The findings assisted in identifying design modifications that could raise
the fan's general efficiency.
4. Discussions:
a. Validation:
The resulting findings were compared with experimental data or analytical solutions,
when available, to confirm the accuracy of the CFD simulations. The comparison
showed good agreement, supporting the CFD model's dependability.
b. Design Optimization:
The insights from the CFD analysis provided helpful information for enhancing the
design of the propeller fan. Engineers might increase the fan's efficiency and decrease
flow losses by modifying variables such blade shape, rotational speed, and inlet/outlet
combinations.
Performance Improvement:
The CFD results gave a deeper understanding of the flow behavior, allowing performance bottlenecks
to be found. This knowledge made it easier to create methods to limit flow separation, lessen
turbulence, and enhance overall fan performance.

Conclusion : 
The literature review presented in this study provides a comprehensive and insightful analysis of the
current state-of-the-art research on the application of computational fluid dynamics (CFD) in the
analysis of propeller fans. Through a meticulous examination of various scholarly articles and
research papers, we have gained a deeper understanding of the significant contributions CFD has
made to the design and optimization of propeller fans in diverse engineering applications.

The findings from this review clearly demonstrate the vital role that CFD simulations play in
elucidating the intricate flow behavior, pressure distribution, and performance characteristics of
propeller fans. Researchers across different domains have effectively employed CFD as a powerful
tool to explore the impact of crucial design parameters on fan performance. This has resulted in the
development of more efficient and environmentally friendly fan designs, thus addressing the pressing
need for sustainability and energy conservation in the industrial sector.

Furthermore, the review highlights the emerging trend of coupling CFD with advanced optimization
techniques to achieve enhanced fan designs that fulfill specific performance objectives. The
integration of genetic algorithms, multi-objective optimization, and other evolutionary approaches has
facilitated the exploration of complex design spaces and the identification of optimal solutions. As a
result, CFD-driven optimization has substantially contributed to the advancements in propeller fan
technology, paving the way for innovative and high-performance solutions.

While this literature review reveals numerous accomplishments in the CFD analysis of propeller fans,
it also identifies certain challenges that warrant attention. The accuracy and reliability of CFD
simulations heavily rely on factors such as grid resolution, turbulence modeling, and boundary
conditions. Addressing these issues remains a critical task for researchers to ensure the credibility of
CFD predictions and to align them with experimental data.
In conclusion, this literature review establishes the indispensability of CFD analysis in the
investigation and enhancement of propeller fan aerodynamics and design. The integration of CFD
simulations with optimization techniques has driven significant progress in the field, resulting in the
development of highly efficient and performance-driven propeller fans. As we move forward,
continuous efforts to overcome existing challenges will further strengthen the reliability and
applicability of CFD methodologies in the domain of propeller fan analysis and design. The insights
obtained from this review serve as a solid foundation for future research endeavors, encouraging
further innovation and advancement in propeller fan technology through CFD-driven insights.

References

[1] “COMPUTATIONAL FLUID DYNAMICS SIMULATION OF PROPELLER FAN” by Pradeep

Shetty, Trupti P. Wani

[2] “Model and full scale CFD analysis of propeller boss cap fins (PBCF)” by Takafumi Kawamura,
Kazuyuki Ouchi, Susumu Takeuchi.

[3] “CFD Analysis of Propeller-Rudder Interaction” by Andrea Di Mascio, Giulio Dubbioso, Roberto
Muscari, Mario Felli

[4] “CFD Analysis of Ducted-Fan UAV Based on Magnus Effect” by Jie Zhao, Qingming Hou, Hongzhe
Jin, Yanhe Zhu, and Ge Li

[5] “CFD Analysis of Axial Flow Fans with Skewed Blades” by Dushyant Dwived1, Devendra Singh
Dandotiya

[6] “CFD Analysis for Ducted Fans with Validation” by Chung Chang, R. G. Rajagopalan

[7] “Computational Fluid Dynamics Simulation for Propeller” by Diego ALMAZO, Ricardo
RODRÍGUEZ JORGE, Jolanta MIZERA-PIETRASZKO