repot on axial fan of wind tunnel

0
Table of Contents
Tables of Figures.......................................................................................................................3

1. Summary............................................................................................................................ 4

2. Theory................................................................................................................................ 5

2.1 Parts of wind tunnel......................................................................................................5

3. Market Review....................................................................................................................6

3.1 Preface......................................................................................................................... 6

3.2 Scope........................................................................................................................... 6

3.3 General classification of turbomachinery......................................................................6

3.4 Product analysis...........................................................................................................7

3.5 Pumps.......................................................................................................................... 7

4. Design Recommendation...................................................................................................9

4.1 Scope........................................................................................................................... 9

4.2 Current turbomachine...................................................................................................9

4.3 Engineering design.....................................................................................................10

4.3.1 Technical............................................................................................................. 10

4.3.2 VSD control..........................................................................................................10

5. New Design calculation of axial fan for wind tunnel.........................................................11

5.1 Calculation of angular speed......................................................................................12

5.2 Specific angular speed...............................................................................................12

pg. 1
 5.3 Axial fan diameter calculation.....................................................................................12

5.4 Hub diameter calculation............................................................................................13

5.5 Fan span length calculation........................................................................................14

5.6 Head Calculation........................................................................................................15

5.7 Required power calculation........................................................................................15

5.8 Axial flow area............................................................................................................ 15

5.9 Axial flow velocity calculation.....................................................................................15

5.10 Rotor mean speed...................................................................................................15

5.11 Tangential velocity calculation................................................................................ 15

5.12 Blade pass frequency..............................................................................................16

5.13 Calculation of flow coefficient..................................................................................16

5.14 Sound power level[6]...............................................................................................16

5.15 Sound pressure level.............................................................................................. 16

6. Results............................................................................................................................. 17

7. MATLAB Calculation results.............................................................................................21

8. References....................................................................................................................... 22

9. Appendix.......................................................................................................................... 24

9.1 MATLAB Code........................................................................................................... 28

pg. 2
Tables of Figures

Figure 1 Components of wind tunnel[3].....................................................................................5

Figure 2 Tip clearance vs mechanical efficiency of axial fan [4]..............................................12

Figure 3 Cordier diagram, for fans [5]......................................................................................13

Figure 4 Hub ratio for axial fan [5]........................................................................................... 14

Figure 5 Effect of air flow on fan diameters and other parameters..........................................18

Figure 6 Effect of air pressure on Fan diameter, Hub diameter and specific speed................18

Figure 7 Effect of air pressure on axial flow velocity & power.................................................18

Figure 8 Effect of Hub ratio on number of blades (at 5000 rpm)..............................................19

Figure 9 Effect of axial fan speed vs brake horse power & specific speed..............................19

Figure 10 Effect of axial fan speed on Different parameters...................................................20

Figure 11 Graph between axial fan speed vs sound pressure level........................................21

Figure 12 Results obtained from MATLAB..............................................................................21

pg. 3
1. Summary

This experiment is about axial fan is analyzed in terms of cost, specifications, efficiency,

practicality and furthermore is technical design is done. For that purpose, using the design

equations available in literature are used for developing MATLAB code and all the required

parameters are properly analyzed and graphs are plotted for further improvement. It is

assumed that requited operating pressure is 1170Pa, flow of air is taken as 7.5m3/sec and

maximum operating speed is 5000 rpm. From the calculations, it is clear that axial fan

diameter is 610mm, Hub diameter is 185mm, whereas hub ratio from graph is 0.3. Required

brake horse power (assuming no power losses) is 8775W and flow area is 0.26m2, axial flow

velocity which is calculated is 28.31 m/sec, flow coefficient is 0.177.

pg. 4
2. Theory

This experiment involves measurement of pressure distribution using the wind tunnel. Wind

tunnels are used vastly in aerodynamic applications[1]. For this purpose, a prototype of

practical model is developed and finally is tested in the wind tunnel to find out the values of

coefficient of drag as well as lift forces. NASA, one of the top space research company uses

wind tunnel for models of both aircraft as well as spacecraft.

2.1 Parts of wind tunnel

The basic components of wind tunnel are mentioned below [2],

 Fan driven unit / motor

 Flow straightener / settling chamber

 Contraction

 Test section

 Diffuser

 Rotating vanes

The following figure delves both schematic of wind tunnel as well as practical model,

Figure 1 Components of wind tunnel[3].

pg. 5
3. Market Review

3.1 Preface

Turbomachinery systems are essential to many industries such as power generation, aerospace,

mining, oil and gas. Turbomachines harness the energy of fluids and exchange this energy with a

rotor. Turbomachinery refers to the class of machines that either extract energy (turbines) or impart

energy (pumps or fans). (SimScale, 2023).

3.2 Scope

This section will encompass a comprehensive evaluation of the current market conditions and trends

within the turbomachine sector of engineering. It will focus on product analysis for various types of

turbomachines, advantages, and limitations on factors such as energy efficiency, cost, practicality

(such as maintenance requirements) and lifecycle.

3.3 General classification of turbomachinery

The most appropriate turbomachine design is influenced by the specific conditions or requirements of

fluid flow, including the head pressure and the volumetric flow rate. The range of flow conditions can

vary from high head and low flow to low head and high flow and include flows from high-speed jets at

relatively low rates to medium to high flow rates, which are typical classifications for turbines. Fluid

pumps are designed to efficiently increase the fluid's pressure. The design of these pumps is affected

by the fluid's flow path through the machine, which then in turn shape the pumps construction. Types

of pumps include both rotary dynamic and displacement dynamic pumps (variable displacement and

positive displacement), with rotary dynamic pumps being the more common type. Rotary dynamic

pumps are categorized based on the shape of the impeller. These pumps have rotating shafts to which

variously shaped blades or impellers are attached, creating flow patterns that range from purely radial

to purely axial. Conversely, displacement dynamic pumps move fluid from the inlet to the outlet in

pg. 6
discrete volumes whilst simultaneously increasing the fluid's pressure through compression. (Round,

2004).

3.4 Product analysis

Pump or turbine selection is a multi-faceted process. What may work in one situation may not work in

a different situation with the same product. In the case of wind tunnels, a crucial characteristic is the

quality of flow inside the test chamber, and the three main criteria to define them are maximum

achievable speed, flow uniformity, and turbulence level (Ahmed et al, 2013). Essentially, the aim is to

achieve a controlled, predictable flow. In the case of pump selection for a water system (or otherwise),

there are many components to consider, such as power supply, the pumps themselves, the piping

network or distribution system, storage reservoirs, and control systems. The components must be

sized appropriately for the given system to operate effectively. The three main factors to size a water

pump include flow, pressure (head, in metres) and motor power, in kW. (Beverly, 2009).

3.5 Pumps

Pumps such as centrifugal pumps used for the movement of water or slurry employ a well-

documented and studied process to select the right product. It is first important to understand that

changes in the demand of the system will require an increase in power and can be observed by an

increase in current draw if the system is connected to a suitable control interface. Pumps can only

operate along their curve for a given impellor size and RPM, and as such the intersection of the

system curve to the operating curve, determined through mathematical analysis of the piping network

and storage reservoirs (the total dynamic head, TDH), determines the duty point of that pump. If any

changes in the system were to occur, such as a loss of suction head or the closing/opening of valves,

the duty point will move up or down the curve. (Bachus et al, 2003). The pump selection process

should ensure that a change of conditions will not adversely affect the performance of the pump or

lead to a power draw larger than the pump can handle.

pg. 7
Typically speaking, an engineer will analyse the piping system and power infrastructure first, noting the

pipe bends, pipe diameter, available suction head (otherwise know as net positive suction head

available– NPSHa), pipe material, elevation, and available power. A system curve can then be

calculated, with all these values as inputs. These values are all important as they determine the fluid

dynamics of the system. These days, computer software can be utilized to analyse pump systems to

aid in selection. Once the system curve is calculated, it can be overlayed on many different pump

curves which have been empirically predetermined, the aim is to ensure the duty point sits at or

around the best efficiency point (BEP). If the pump is poorly selected and the operating range is

expected to sit far from the BEP, then accelerated wear of components inside the pump will lead to

undesirable maintenance costs, unstable operation, and lower efficiency (Beverly, 2009).

Selection of pumps may also lead to the decision to situate pumps in series (increase pressure) or

parallel (increase flow), while one of these pumps on their own may not meet the system

pg. 8
requirements, multiple pumps may achieve this while still operating at an acceptable duty point.

Alternatively, a variable speed drive (VSD) can be used. This, along with a suitable control system, will

increase or decrease the pump RPM, essentially moving the pump curve up or down, to ensure the

duty point remains at the desirable position for flow and pressure.

4. Design Recommendation

4.1 Scope

The primary objective of this design is to outline the technical design of a turbomachine which

meets the specific operational requirements of the wind tunnel located at Charles Darwin

University Casuarina campus. This includes the cost considerations, efficiency, practicality

(e.g., maintenance requirements).

4.2 Current turbomachine

The current wind tunnel fan is an AFBD 760 Axial Flow Fan has a duty flow rate of 27000

m3/hr at 1000 Pa. It is driven by an 18.5 kW motor at 1440 RPM. The impeller is a 750mm

Polypropylene impeller. The fan is electronically balanced, making it ideal for this application

as unbalance vibrations can effect experimental data and will also assist with reducing noise.

In addition, the carefully designed “aerofoil” profile further assists with noise reduction.

pg. 9
4.3 Engineering design

4.3.1 Technical

The new fan must meet the current fan criteria, however there is a request for further improvement.

Possible improvements which could be made are:

4.3.2 VSD control

1. Higher pressure performance

2. Higher flow performance
3. Quieter operation
4. Easier maintenance
5. Better affordability
6. Higher quality parts

A VSD would allow the fan to operate at different duty points. This is useful as it would allow additional

parameters for experimentation. For example, a wind tunnel experiment could supply different air

pg. 10
pressures, and flow rates, giving additional data points. A VSD is an expensive addition, however, will

give the greatest benefit as an upgrade. A VSD may also lead to energy savings and reduced wear,

this is because the fan may not always need to run at full speed depending on the experiment

requirements. To achieve higher flow, additional fans could be placed inside the wind tunnel as a

“matrix”. It will allow the fan to move a larger volume of air, useful where high flow scenarios are

preferred. A fan which can supply higher pressure may have more blades or a different pitch, although

lower efficiency at higher speeds (due to higher air resistance) and may be noisier. The new fan

should be designed with maintenance in mind. The wind tunnel is presumably used often. This would

lead to increased wear on the parts. A lifecycle analysis should be completed to ensure that the stress

factors on all the components are within the right range for the expected lifecycle of the equipment.

Parts such as shafts, couplings, impellors, and drives should be easily replaceable and use parts that

are of good quality. A lower cost fan may be desirable; however, consideration should be given to the

quality of the parts.

5. New Design calculation of axial fan for wind tunnel

m3
Required flow of air=Q=27000 =7.5 m3/ sec
hr

Pressure=P=1170 Pa

Assuming maxium operating speed=N =5000 rpm

kg
Air density= ρair =1.14
m3

kg
Water density =ρw =1000
m3

pg. 11
 Figure 2 Tip clearance vs mechanical efficiency of axial fan [4].

5.1 Calculation of angular speed

2∗3.1416∗5000 rad
Angular speed =ω= =523.6
60 sec

5.2 Specific angular speed

ω √Q
Specific Angular speed=ωs =
( gH )0.75

ω√Q
ω s=
( )P 0.75
ρ air

523.6∗√7.5
ω s=
( )
1170 0.75
1.14

ω s=7.9 rad /sec

5.3 Axial fan diameter calculation

From the figure below, using the known value of ∆ s comes about 1.3 ,

pg. 12
 Figure 3 Cordier diagram, for fans [5].

∆ s√Q
D fan =
( gH )0.25

1.3∗√ 7.5
Dfan =
( 1170 )0.25

Dfan =0.608 m 610 mm

5.4 Hub diameter calculation

To calculate the Hub diameter, we should know Ns, as follows;-

N √Q
Ns=
( ) P 0.75
ρw g

pg. 13
 5000 √ 7.5
Ns=
( )
0.75
1170
1000∗9.81

4
N s =6.74∗10

From the diagram given below, hub ratio is selected from graph as per calculated Ns above,

Figure 4 Hub ratio for axial fan [5].

We get hub ratio, v=0.3, so calculating the hub diameter

Dhub =v∗D fan

Dhub =0.3∗610

Dhub 185 mm

5.5 Fan span length calculation

D fan −D hub 610−185

b= = ≈ 215 mm
2 2

pg. 14
5.6 Head Calculation

P 1170
H= = ≈ 105 mm
ρair g 1.14∗9.81

5.7 Required power calculation

m
Power=QP=7.5 ∗1170 Pa
sec

Power=8775 W =8.775 kW (assuming no losses )

5.8 Axial flow area

π 2
Af=
4
( D fan−D hub )
2

π
Af=
4
( ( 0.610 )2−(0.1852) )

2
A flow =0.264 m

5.9 Axial flow velocity calculation

Q 7.5
Va= = =28.13 m/sec
A flow 0.264

5.10 Rotor mean speed

2∗3.1416∗0.610
∗5000
2
U mean =
60

m
U mean =159
sec

pg. 15
5.11 Tangential velocity calculation

U mean∗D fan
Velocit y tangent =
2

159∗0.610
Velocit y tangent =
2

Velocit y tangent ≈ 160 m/ sec

5.12 Blade pass frequency

No . of blades∗Angular speed
BPf =
60

10∗523.6
BPF=
60

BPF=87.26 Hz

5.13 Calculation of flow coefficient

Axial flow velocity

φ=
rotor mean speed

28.13 m/s
φ=
159.36 m/s

φ=0.177

5.14 Sound power level[6]

PWL=56=30 log ( 1000

N
)+ log ( BHP ∈HP )
PWL=56+ 30 log ( 5000
1000 ) + log (
746 )
15708

pg. 16
 PWL=107.33 dB (A )

5.15 Sound pressure level

SPL=PWL−20∗log ( R )

SPL=107.33−20∗log ( 1.5 m )

SPL=99.22 dB ( A )

6. Results
Flow area (m2)

0.4

0.2

0
1 2 3 4 5 6 7 8 9 10
volume flowrate of air (m3/s)
Specific speed (m/s)

104
8

2
1 2 3 4 5 6 7 8 9 10
volume flowrate of air (m3/s)

pg. 17
 800 250

Hub diameter(mm)
Fan diameter(mm) 200
600
150
400
100

200 50
0 2 4 6 8 10 0 2 4 6 8 10
volume flowrate of air (m3/s) volume flowrate of air (m3/s)
10 4
Specific speed (m/s)

2
1 2 3 4 5 6 7 8 9 10
volume flowrate of air (m3/s)
Figure 5 Effect of air flow on fan diameters and other parameters.

pg. 18
 Hub diameter(mm)
Fan diameter(mm)
1200 1200

1000 1000

800 800

600 600

400 400
0 500 1000 1500 0 500 1000 1500
Pressure of air (Pa) Pressure of air (Pa)
Specific speed (m/s)

0.8

0.6

0.4

0.2
0 500 1000 1500
Pressure of air (Pa)

Figure 6 Effect of air pressure on Fan diameter, Hub diameter and specific speed.

35 12000

30 10000
Axial flow velocity (m/s)

25 8000
Power(Watts)

20 6000

15 4000

2000
10

0
5 0 500 1000 1500
0 500 1000 1500
Pressure of air (Pa)
Pressure of air (Pa)

Figure 7 Effect of air pressure on axial flow velocity & power

pg. 19
 600

500

Number of impeller blades,Zb 400

300

200

100

0
1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1
Hub ratio, v

Figure 8 Effect of Hub ratio on number of blades (at 5000 rpm)

8
Specific speed (m/s)

0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Axial fan speed (rpm)
Brake horse power(Watts)

4
10
2

1.5

0.5

0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Axial fan speed (rpm)

Figure 9 Effect of axial fan speed vs brake horse power & specific speed.

pg. 20
 8 16000

7 14000

Brake Pass Frequency(Hz)

6 12000
Blade solidity ratio)

10000
5

8000
4

6000
3

4000
2
2000
1
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Axial fan speed (rpm)
Axial fan speed (rpm)
Flow coefficient)

10

0
Sound pressure level (db(A))

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Axial fan speed (rpm)

100

98

96

94
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Axial fan speed (rpm)

Figure 10 Effect of axial fan speed on Different parameters.

pg. 21
 107.5

107

106.5

Sound power level(db(A) 106

105.5

105

104.5

104

103.5

103
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Axial fan speed (rpm)

Figure 11 Graph between axial fan speed vs sound pressure level.

7. MATLAB Calculation results

Figure 12 Results obtained from MATLAB

pg. 22
8. References

 SimScale. (2023, August 11). What is Turbomachinery?. Retrieved from,

https://www.simscale.com/docs/simwiki/cfd-computational-fluid-dynamics/what-is-

turbomachinery/

 Cadence Design Systems. (n.d.). An Introduction to Turbomachinery Aerodynamics.

System Analysis Blog. Cadence. Retrieved from, https://resources.system-

analysis.cadence.com/blog/msa2023-an-introduction-to-turbomachinery-aerodynamics

 Round, G. F. (George F. (2004). Incompressible flow turbomachines design, selection,

applications, and theory. (1st ed.). Elsevier Butterworth Heinemann.

 Bachus, L., & Custodio, A. A. (2003). Know and understand centrifugal pumps.
Elsevier.

 Ahmed, N. A. (2013). Wind Tunnel Designs and Their Diverse Engineering

Applications (N. A. Ahmed, Ed.). IntechOpen.

 Beverly, R. P. (2009). Pump selection and troubleshooting field guide. American Water

Works Association.

 Montazerin, N., Akbari, G., & Madmoodi, M. (2015). Developments in turbomachinery

flow : forward curved centrifugal fan (1st ed.). Woodhead Publishing.

 [1] M. A. Azmie, “School of Mechanical Engineering MCEN3002 Applied Fluid

Mechanics Drag on Cylinder Laboratory Report,” no. August, 2021, doi:

10.13140/RG.2.2.10043.75042.

 [2] M. Okiishi and H. Rothmayer, Fundamentals of Fluid Mechanics.

 [3] E. Vardoulakis, D. Karamanis, M. N. Assimakopoulos, S. N. Boemi, and G.

pg. 23
 Mihalakakou, “Moisture sorption properties of modified porous clays for roof

evaporative cooling applications,” Int. J. Vent., vol. 10, no. 2, pp. 185–194, 2011, doi:

10.1080/14733315.2011.11683947.

 [4] H. Ö. KEKLİKOĞLU and IN, “DESIGN, CONSTRUCTION AND

PERFORMANCE EVALUATION OF AXIAL FLOW FANS,” no. September, 2019,

[Online]. Available:

https://www.minsal.cl/wp-content/uploads/2019/01/2019.01.23_PLAN-NACIONAL-DE-

CANCER_web.pdf

 [5] L. E. Richter, A. Carlos, and D. M. Beber, Principals of Turbomachinary.

 [6] H. P. Corporation, “The Basics of AXIAL FLOW FANS,” BioPharm Int., no.

February. pp. 26–30, 2006.

pg. 24
9. Appendix

pg. 25
pg. 26
pg. 27
pg. 28
9.1 MATLAB Code

clc
clear all;

Q=27000/3600; %flow of air,

P =1170; %pressure in pascal
N=5000;
rho_a=1.14 %density of air in kg/m3
rho_w=1000 %density of water in g/m3

omega = (2*3.1416*N)/(60);

omega_s=(omega*sqrt(Q))./((P/rho_a).^(0.75)) %specifc speed cal

%Fan diameter calculation

del_s=1.3
Df=((del_s*sqrt(Q))./(P.^0.25))*1000

%Hub diameter calculation

Ns=(N*sqrt(Q))./((P./(rho_w*9.81)).^(0.75))
v=0.3
Dh=v*Df

% plot(x,y1,'g',x,y2,'b--o',x,y3,'c*')

%Head calculation
H=(P)/(rho_a*9.81) %head in meters

%Power calculation
Power=Q*P %in watts
blades=10
b=(Df-Dh)/2

%Flow area for the axial flow

Af=(3.1416/4)*((Df/1000).^2-(Dh/1000).^2) % m2

%xial flow velocity

Va=(Q./Af) %m/s

%rotor mean speed

Um=(2*3.1416*0.305*N)/(60)%m/s
velocity=sqrt(2*rho_a*P) %m/s
Velocity_tangent=(omega*(Df/1000))/2 %m/s
phi=Va./Um %flow coefficient
s=(3.1416*Df)/blades
c=(phi.*s)./1.2 %mm

%Blae olidity
sigma=c/s

%Brake horse power calculation

tau=30
bhp=omega*tau %in watts

pg. 29
%efficiency
eta=(rho_a*9.81*Q*H)./(bhp)*100 %n percentage

%blade pass frequency

bpf=(blades*omega)/(60) %Hz
pwl=56+30*log(5000/1000)+log(bhp/746) %sound power level
spl=pwl-20*log(1.5) %dB(A)

Effect of Axial fan speed on different parameters

subplot(2,1,1)
plot(N,omega_s)
xlabel('Axial fan speed (rpm)')
ylabel('Specific speed (m/s)')

subplot(2,1,2)
plot(N,bhp)
xlabel('Axial fan speed (rpm)')
ylabel('Brake horse power(Watts)')

figure
plot(N,bhp)
xlabel('Axial fan speed (rpm)')
ylabel('Brake Pass Frequency(Hz)')

subplot(2,1,1)
plot(N,phi)
xlabel('Axial fan speed (rpm)')
ylabel('Flow coefficient)')

subplot(2,1,2)
plot(N,spl)
xlabel('Axial fan speed (rpm)')
ylabel('Sound pressure level (db(A))')

figure
plot(N,pwl)
xlabel('Axial fan speed (rpm)')
ylabel('Sound power level(db(A)')

figure
plot(N,sigma)
xlabel('Axial fan speed (rpm)')
ylabel('Blade solidity ratio)')

figure
plot(P,Power )
xlabel('Pressure of air (Pa)')
ylabel('Power(Watts)')

figure
plot(P,Va )
xlabel('Pressure of air (Pa)')
ylabel('Axial flow velocity (m/s)')

Effect of Pressure on different parameters

pg. 30
subplot(2,1,1)
plot(P,Af)
xlabel('Pressure of air (Pa)')
ylabel('Flow area (m2)')

subplot(2,1,2)
plot(P,Af)
xlabel('Pressure of air (Pa)')
ylabel('Specific speed (m/s)')

subplot(2,2,1)
plot(P,Df)
xlabel('Pressure of air (Pa)')
ylabel('Fan diameter(mm)')

subplot(2,2,2)
plot(P,Df)
xlabel('Pressure of air (Pa)')
ylabel('Hub diameter(mm)')

figure
plot(P,Power )
xlabel('Pressure of air (Pa)')
ylabel('Power(Watts)')

figure
plot(P,Va )
xlabel('Pressure of air (Pa)')
ylabel('Axial flow velocity (m/s)')

pg. 31