Experiment No 11

To determine the characteristics curves of axial fan operating at a varying speed

11.1 Introduction
11.1.1 Axial Fan
An axial flow fan is a type of industrial fan used to cool machines and equipment which heat up after
use. Axial flow fans are the type of compressor, which produces airflow parallel to the axis, thus the
name. These fans are equipped with impellers, which suck the air in and discharge in the same
direction of the axis.
There are AC as well as DC axial flow fans. It may be designed in different ways such as with a duct
or a mounting ring, and so on, depending upon the requirement. So, there are different standard
designs which can be customized based on your device and installation type. The materials and
accessories used for the fan are decided on these and other physical factors such as the environment
it would be exposed to, temperature, moisture, pressure, and so on. This post discusses various
designs of axial flow fans, and general features.
Axial fans generally comprise fewer blades (two to six) than centrifugal fans. Axial fans commonly
have larger radius and lower speed (ω) than ducted fans (esp. at similar power.[1]

11.1.2 Components of Axial Fan

The most basic part of an axial flow fan is the motor. Other than that it has ball bearings, blades, and
impellers. The fan has a housing or an enclosure which protects it from external damage, spillage,
shock, vibration, and so on. The enclosure is metallic and made of steel, aluminum, or alloys. The
impellers are usually made of cast aluminum with black paint, thermoplastic, or steel, and designed
to be corrosion resistant. The thermoplastic impellers are generally not considered ideal for
commercial applications, so they are usually reserved for residential applications. The propellers
feature blades. There can be 2 to 20 blades on the propellers. The fan is connected to a motor drive,
which is usually placed in a housing parallel to the direction of airflow. The blades are usually made
of aluminum. These fans are designed to be resistant to extreme temperatures, flames, shock,
corrosive materials, and so on. A few common accessories of this fan include suitable connecting
points, silencer, protection grill, counter flange, vibration controller, feet for the required positioning,
and a variable inlet vane.[2]
11.1.3 Design of Axial Flow Fans
As mentioned, the fan has various standard designs. Here are a few pointers:
 The fans may be duct mountable or wall mountable.
 Ducted fans have a duct through for seamless airflow.
 The ring mountable fans allow the airflow from one big enough area to another; so, it is suitable
for large spaces.
 The circulator fan has rotating impellers, which are typically used in ceiling fans.
 Axial flow fans offer large airflow rates at low pressures because of their working principle. The
blades of these fans draw air parallel to its axis and move it in the forward in the same direction
within the axis of the fan.

11.1.4 How Does an Axial Flow Fan Works?

Axial fans work like an aircraft wing, which possesses an airfoil shape and produce lift. Due to the
airfoil shape of the wing, the air above and below it are divided and have different air velocities. This
is because the air in the above section travels farther than air in the bottom section. The air above has
a high air velocity, which produces a high dynamic force and low static pressure. Against this, the air
in the below section has low air velocity and produces a high static pressure. These pressure
differences create the lift. Now coming to the axial fan, the blades of the propellers act like wings,
and they push air forward, thereby causing a lift. As a result of this lift, the air is propelled, as well as
pushed back. The speed of air continues to increase up to a point even after the air leaves the fan.
The airflow is great at the exit than at the entry point.[3]

11.1.5 Some General Characteristics of Axial Flow Fans

These fans are typically used for sucking hot air from heat generating machines, trenches, and so on.
They are also used for ventilation in enclosed spaces. These fans find a great application in quiet
zones. Here are some general features of axial flow fans.
 These fans have a wide size range from 25mm to 250mm.
 These fans usually have ball or sleeve bearings which can last up to as high as 50,000 hours and
at reasonably high temperatures.
 Their operating range is usually from -10 to +70, depending upon the bearing type.
 They operate quietly without noise, and have good dielectric strength.
 They require minimal power input to operate.
 Apart from cooling industrial equipment, they find applications in diverse segments such as snow
making machines, vending machines, refrigeration systems, HVAC systems, and so on.[4]

11.1.6 Applications of Axial Flow Fans

Axial fans are generally used for cooling applications like the ones mentioned below:
 Process cooling in systems or machinery
 Spot cooling of transformers and generators and industrial equipment
 Ventilation in warehouses, factories, foundries, laundries, garages, equipment rooms, and engines
 Cooling work areas where heat is produced
In addition to this, industrial axial fans are also used for removing toxic gases and fumes from:
 Paint spray booths
 Welding booths
 Kilns, steel mills, and forges
 Paper mills or industrial parts washers[5]

11.1.7 Benefits of Using Industrial Axial Flow Fans

11.1.7.1 Efficient Airflow:
Industrial axial flow fans assure efficient airflow, which is why they are cooling towers and exhausts.
The cooling towers cannot dissipate heat if the airflow is not proper. The water system and fill
material inside these fans operate properly due to a consistent airflow from the cooler fan, which is
an axial fan. The axial fans can produce a large volume of air at a regular pace and they also ensure
even air circulation due to the airfoil blades.

11.1.7.2 Variable Speed:

The speed of axial flow fans can be easily altered to suit the needs of the cooling tower or exhaust
fans. The fans will continue to produce high airflow even if the speed is decreased. Against this,
decreasing the speed can have a direct impact on the airflow of centrifugal fans.

11.1.7.3 Durable Construction:

Most industrial axial fans are made from aluminum, which makes them durable, reliable,
lightweight, and user-friendly at the same time. Sometimes they are also made of stainless steel,
which improves their performance in harsh environments. Many manufacturers provide industrial
axial fans equipped with spark-resistant and cast aluminum made propellers, which assures their
safety in high-temperature applications. Their durable construction is one of the prime reasons for
employing these fans in ships, aircraft, helicopters, and hydrofoils.

11.1.7.4 Quick Maintenance:

Axial fans possess simpler designs than other industrial fan types. These fans have simple and open
designs. Thus, any operational issues that arise can be easily identified and rectified. This is one of
the reasons why these fans are widely used in industrial cooling and exhaust applications.

11.1.7.5 Improved Lifespan of Mechanical Components:

These fans possess compact footprint and lightweight designs than their earlier counterparts, which
helps improves the lifespan of different mechanical components in it. Generally, the axial fans have
improved lifespan than other industrial fans due to their high mechanical strength and optimal
designs.

11.1.7.6 Quieter Than Most Other Industrial Fans:

Industrial axial flow fans produce low mechanical noise than conventional fans. This makes it an
ideal choice for applications where noise can be a big concern.
If you are an OEM and have newly installed equipment which require axial flow fans, ensure you
source them from a reliable manufacturer and supplier. Also, ensure they have features which meet
your specifications. Sofasco designs, develops, and manufactures AC and DC axial fans in a huge
size range, along with other integrated cooling solutions which can be customized to suit your
requirements.[6]
11.1.9 Nomenclature
Fan Pressure Drop dps
Fan Speed n
Inlet Temperature Ta
Barometric Pressure Pa
Acceleration due to gravity g
Inlet cross-sectional area A1
Outlet cross-sectional area A2
Density of air ρ
Volume flow rate Q
Differential Pressure P
Inlet duct air velocity v1
Outlet duct air velocity v2
Fan total pressure Ptf
Mechanical power input Pin
Fan power output Pu
Overall Efficiency Egr

11.2 Literature Review

11.2.1 Analytical Review
A comprehensive method of estimating the performance of axial flow steam and gas turbines is
presented, based on analysis of linear cascade tests on blading, on a number of turbine test results,
and on air tests of model casings. The validity of the use of such data is briefly considered. Data are
presented to allow performance estimation of actual machines over a wide range of Reynolds
number, Mach number, aspect ratio and other relevant variables. The use of the method in connection
with three-dimensional methods of flow estimation is considered, and data presented showing
encouraging agreement between estimates and available test results. Finally ‘carpets’ are presented
showing the trends in efficiencies that are attainable in turbines designed over a wide range of
loading, axial velocity/blade speed ratio, Reynolds number and aspect ratio.[7]
According to First Law of Thermodynamics:

( )
2
v
−W s=d + gdz +∫ vdp+ F
2

Mechanical Change in Change in

Shaft Work K.E of fluid P.E of fluid

dp P 2−P1
Change in P.E =
ρ
or
ρ
P2 = Discharge Outlet
P1 = Fan inlet
2 2
(v¿ ¿2 −v 1 )
W a= ρ+(P 2−P1)¿
2

ρ remains constant for incompressible flow.

Air velocity Calculation:

C d π d × √2 ρ P o
2
Qv =
4ρ
 Inlet velocity:
Qv
v 1=
A1
r 1=50 mm
 Outlet velocity:
Qv
v 2=
A2
r 1=37.5 mm

Development of a fast and accurate tool to estimate the performance of axial flow turbines in all
range of working conditions including choked region is of great interest in the design steps of
turbines. Mean-line (one-dimensional) analysis is one of the solutions that is computationally cost-
effective along with producing accurate results. However, the development of a mean-line model that
able to solve the flow in a choked turbine (one-row chocking and multi-row choking) is a
challenging problem. This study presents a new algorithm for mean-line analysis of axial
flow turbines with a set of well-posed boundary conditions, i.e., the inlet total pressure, the inlet total
temperature, inlet flow angle, and outlet static pressure and calculates the flow condition through the
turbine row-by-row. The proposed algorithm is implemented in an object-oriented C++ code
named Axial Turbine Simulator (ATSim). The results of ATSim program is validated and verified
under various working conditions, e.g., low and high-pressure ratios (choking condition), for four
different turbine configurations including two uncooled single-stage turbines, an uncooled two-stage
turbine, and a cooled three-stage turbine. ATSim provide good consistency with previous
experimental and numerical studies. Moreover, the results show that ATSim is capable of estimating
the performance of the turbine in a very short time over a wide range of working conditions,
including choking (one-row choking or multi-row choking) region.[8]
11.2.2 Modeling and simulation
The procedure of the parametric design and numerical simulation is developed to enhance greatly fan
design efficiency, which can generate high quality hexahedral mesh automatically. The numerical
simulation can be performed automatically and the aerodynamic performance of the fan can be
characterized without using any other tools. The developed procedure can be employed to the
optimization design of the fan. Based on the procedure of the parametric design and numerical
simulation, the influences of various design parameters on the aerodynamic performance of the fan
are investigated deeply. Such influences can provide physical insight into the flow characteristics of
the fan. The multiparameter constrained optimization procedure based on the combination algorithms
of design of experiments, response surface models, genetic algorithm, and mixed integer
optimization, is carried out aiming at the fan to maximize its coefficient of flow rate over the
operating range rather than at a single operating point with parallel computational fluid dynamics.
Results show that the aerodynamic average flow rate coefficient of the optimal fan is increased by
14.5% compared to the initially designed fan. This paper demonstrates the potential of the proposed
procedure to be applied widely in industry for the purpose of improving work efficiency among
engineers.
One of the crucial steps in the automated design optimization procedure is the selection of an
effective way to describe parametrically the fan geometry. The fan geometry, here, is parameterized
by a simple yet very efficient generic method using fourth-order parametric spline curves. The
locations of the spline control points are picked to minimize the discrepancy between the spine
definition of the blade geometry and the existing discrete target blade shape. This general
methodology can be applied to parameterize arbitrary curve and shape in universal design problem.
The design variables could be defined as a modification either to the existing original shape or to an
absolute shape.
The blade geometry is obtained by linear interpolation of the seven blade profiles from hub to tip.
Each blade profile is defined by a mean line and thickness distributions, and is parameterized by a
fourth-order spine curve. The definition of such a profile is bonded with three parameters (m, p, and
ta) and demonstrated in Fig. The details of these three parameters can be found elsewhere.

By using parametric grid generation, it is possible to conduct the geometry optimization based on the
CFD solution if the 3-D geometry is represented implicitly by functions of the design parameters.
After determining the blade geometry, the entire 3-D geometric dimension is stored for CAD
visualization using spline control points, and then is transformed into Cartesian coordinates lying on
some cutting planes. A grid generation tool uses these coordinates to create the meshes around the
entire blades which are needed by the CFD code. To avoid the grid singularity, the 2-D cross-section
of the single passage is decomposed into a few parts within which quality blocks are generated
without breaking the overall geometry. A general strategy is to use nine blocks for generating H-type
fan mesh, as shown in Fig.

Fig. depicts the grid system of multiblock topology used for the flow analysis within an axial-flow
fan. The single passage grid at the rotor region consists of 35 cells in the stream-wise direction, 32
cells in the blade-to-blade direction, and 26 cells in the span-wise direction. Four cells in the span-
wise direction are distributed between the blade tip and the housing wall with the near-wall
clustering. The first grid point from the nearest wall is located between y+=30 and 120 to validate the
use of the wall function. The mesh is refined adaptively near the boundaries where a large velocity
gradient is expected. The sensitivity of the solution to the grid size is analyzed to ensure the accuracy
of results.

This parameter design system is able to produce quickly different fan configurations, as displayed in
Fig. For these fans, regardless of the grid generation tools, the automatic grid generation of each fan
demands more than 5 min, excluding the time required to build CAD file. In addition, the automatic
grid may be generated on a trial-and-error basis, and then the high quality grids can be attained
accordingly. By contrast, the time required for creating hexahedral mesh of the fan is about 2 min by
the parameter design system. Apparently, the latter reduces greatly the design time by more than
50%. [9]

11.2.3 Experimentation
Two prediction methods for broad-band noise of low-pressure axial fans are investigated. Emphasis
is put on the interaction noise due to ingested turbulence. The numerical large eddy simulation (LES)
is applied to predict the unsteady blade forces due to grid generated highly turbulent inflow; the
blade forces are then fed into an analytical two-dimensional acoustic ducted source model. A simple
semi-empirical noise prediction model (SEM) is utilized for indicative comparison. Finally, to obtain
a database for detailed verification, the turbulence statistics for a variety of different inflow
configurations are determined experimentally using hot wire anemometry and a correlation analysis.
In the limits of the necessary assumptions the SEM predicts the noise spectra and the overall sound
power surprisingly well without any further tuning of parameters; the influence of the fan operating
point and the nature of the inflow is obtained. Naturally, the predicted spectra appear unrealistically
“smooth”, since the empirical input data are averaged and modeled in the frequency domain. By way
of contrast the LES yields the fluctuating forces on the blades in the time domain. Details of the
source characteristics and their origin are obtained rather clearly. The predicted effects of the
ingested turbulence on the fluctuating blade forces and the fan noise compare favorably with
experiments. However, the choice of the numerical grid size determines the maximal resolvable
frequency and the computational cost. As contrasted with the SEM, the cost for the LES-based
method are immense.

The investigated fan consists of a typical low-pressure axial impeller with six NACA 4509-blades,
which is running in a duct-type housing without guide vanes. The impeller outer diameter
is D=299 mm. For all experiments the speed is n=3000 rpm (corresponding to a tip speed Mach
number Ma=𝑢/𝑐0=0.14, with the circumferential speed of the impeller 𝑢=𝜋Dn and the speed of
sound c0). The Reynolds number ReC, based on chord length C and mean flow velocity in the rotating
impeller (roughly w1) varies from 92,000 at the hub to 170,000 at the blade tip. To indicate the fan
operating point the dimensionless flow rate coefficient 𝜙=𝑉˙(𝑢(𝜋/4)𝐷2), in preference to volume
flow rate 𝑉˙ is used. The operating point of maximum efficiency (design operating point)
corresponds to 𝜙=0.179. This operating point or its corresponding volume flow rate was selected for
most measurements within this study. Further details of the fan are listed in.
Speed η 3000 rpm
Volume flow rate 𝑉˙ 0.59 m3/s
Total to static pressure rise Δpts 170 Pa
Total to static efficiency ηts 45%
Impeller diameter D=2ra 0.299 m
Number of blades z 6
Hub/tip ratio ri/ra 0.45
Radial tip clearance s/D 0.0017
Trailing edge thickness d/D ∼0.0017
d/C ∼0.0083
Fluid density (air) ρ 1.2 kg/m3

For four typical inflow configurations depicts fringe plots of the measured local time-mean axial
velocity cx in the reference plane. cx is non-dimensionalized with the averaged axial velocity without
any obstructions 𝑐𝑥,𝑚=𝑉˙/(𝜋𝑟𝑎2-𝜋𝑟𝑖2). RPG2 produces a distribution which is extremely non-
uniform due to the wake/vortex structure downstream of the square-mesh array. The NI yields a more
uniform distribution. When the turbulence control screen TCS is used the core is very uniform but
the boundary layers are clearly detectable at the duct and hub wall. TCS in combination with a HC
and BLR yield a uniform distribution with slightly lower velocities at the duct wall, where the
suction is applied. Each plot shows distortions of the maps at the right-hand side boundary at the 2
o’clock position, corresponding to 𝜃=0°. These are caused by the wake of the second fixed hot-wire
probe, placed slightly upstream at 𝜃=0° as well. Therefore, for the following quantitative analysis of
the data the region from θ=0–5° for all radii is excluded. Fig throws further light on details of the
flow field in the reference plane. It presents—as a function of the radius—circumferentially
averaged (indicated by the bar above the symbol) time-mean velocities, turbulence intensities and
length scales. Clearly, the velocity is almost independent of all turbulence control devices and not
significantly influenced by the radial position. However, turbulence intensity and integral length
scales vary considerably. (Note, that the boundary layer could not be fully detected because of the
absolute size of the hot wire probe.) RPG2 produces turbulence intensities as high as 21%. TCS
reduces Tu¯ down to less than 1% in the core region but not in the vicinity of the duct wall. The
combination of TCS, HC and BLR yields an extremely uniform Tu¯-distribution. At the same time
this combination produces the smallest integral length scales. Clearly, the length scales are the largest
with NI as well as with TCS. As expected, the combination of TCS, HC and BLR produces the
lowest fan noise. Data for all turbulence control devices investigated within this project. In
general, 𝛬𝑥¯ and 𝛬𝑢¯ have the same order of magnitude, but in many cases 𝛬𝑥¯ tends to be slightly
larger than 𝛬𝑢¯. According to Roach several previous workers have found 𝛬𝑥≈1.9𝛬𝑢. In case of
mesh generated turbulence, Roach also presented an empirical correlation 𝛬𝑥/𝑎=0.2Δ𝑥/𝑎, where
Δx is the distance downstream from the turbulence control device and a is the bar width of the mesh
array. Measurements made agree reasonably well with Roach's results. [10]
11.3 Methodology
11.3.1 Experimental Setup
 FM41 Axial fan demonstration
 Orifice
  IFD Interface device

PC

Inlet 
Honeycomb

11.3.2 Procedure
 The software should be on the PC that is used for the experiment and demonstration.
 Check that the IFD7 is positioned beside the FM41, and the power and sensor cables from the
FM41 are connected to the front IFD7 sockets.
 Check that the IFD7 is connected to the suitable main supply, as indicated on the rear of the
device or on the main lead supplied of the device.
 Check that the IFD7 is connected to the PC using the USB cable supplied.
 Switch on the main power to the IFD7. Switch on the power switch on the front of the IFD7.
The PC should be on and the FM41 software should be running.

11.4 Observations and Calculations

Orifice Diff. Fan Diff. Motor Discharge

Fan Setting Fan Speed Air Temp. Density of
Pressure Pressure Power Coefficient
S N T air
P0 Pf Pe Cd

o
% Rpm C Pa Pa W Kg/m3

50 1500 30.1 11.1 14.4 1.9 0.596 1.143

55 1650 30.1 14.4 17.5 2 0.596 1.142
60 1800 30.1 15.5 19.6 2.1 0.596 1.142
65 1950 30.1 18.4 21.8 2.3 0.596 1.142

70 2100 30.1 21.3 23.7 2.5 0.596 1.142

 Fan Inlet Outlet Fan Total Predicted
Fan Power Overall Predicted
Discharge Velocity Velocity Pressure Total
Output Efficiency Discharge
Q Vin Vout Pressure

L/s m/s m/s Pa W % L/s Pa

20.6 1.73 1.73 14 0.30 15.8 41.2 57.4

23.5 1.97 1.97 17 0.41 20.7 46.9 69.8
24.4 2.05 2.05 20 0.48 22.4 48.8 78.6
26.6 2.24 2.24 22 0.58 25.3 53.2 87.1
28.6 2.41 2.41 24 0.68 27.7 57.2 94.9

11.5 Results and Discussions

Fan speed vs Fan Discharge

35

30

25
Fan Discharge

20

15

10

0
1400 1500 1600 1700 1800 1900 2000 2100 2200

Fan Speed

Fan speed vs outlet speed

3

2.5

2
Outlet speed

1.5

0.5

0
1400 1500 1600 1700 1800 1900 2000 2100 2200

Fan Speed
 Fan speed vs Power Output
0.8
0.7
Power Output 0.6
0.5
0.4
0.3
0.2
0.1
0
1400 1500 1600 1700 1800 1900 2000 2100 2200

Fan speed

Fan speed vs Efficiency

30

25

20
Efficiency

15

10

0
1400 1500 1600 1700 1800 1900 2000 2100 2200

Fan Speed

11.6 Conclusion
11.7 References
Axial fan design. Available from: https://en.wikipedia.org/wiki/Axial_fan_design#:~:text=An
%20axial%20fan%20is%20a,axial%20at%20entry%20and%20exit.
2. Funkhouser, J. Axial Flow Fan: Components, Design & General Characteristics. Jul 03,
2020; Available from: https://sofasco.com/blogs/article/axial-flow-fan-components-design-
general-characteristics.
3. A Closer Glimpse at the Working Principle of Axial Fans. Available from: https://nisco.ca/a-
closer-glimpse-at-the-working-principle-of-axial-fans/#:~:text=Axial%20fans%20are%20a
%20type,cause%20air%20to%20flow%20axially.
4. Characteristics of Axial Flow Fan. Available from:
https://www.wheecoolingfan.com/characteristics-of-axial-flow-fan-and-centrifugal-fan.html.
5. Axial Fans for Industrial Applications. Available from: https://www.aireng.com.au/axial-fans-
for-industrial-applications/.
6. THE ADVANTAGES OF AXIAL FANS. Available from:
https://fansandblowers.com/news/The-advantages-of-Axial-F.
7. Craig, H. and H.J.P.o.t.I.o.M.E. Cox, Performance estimation of axial flow turbines. 1970.
185(1): p. 407-424.
8. Shahbazi, A.A., et al., Performance estimation of multi-stage cooled axial flow turbines
under choked conditions. 2023. 230: p. 120828.
9. Jian-hui, Zhou, and Yang Chun-Xin. "Parametric design and numerical simulation of the
axial-flow fan for electronic devices." IEEE transactions on components and packaging
technologies 33, no. 2 (2010): 287-298.
10. Carolus, Thomas, Marc Schneider, and Hauke Reese. "Axial flow fan broad-band noise and
prediction." Journal of sound and vibration 300, no. 1-2 (2007): 50-70.