THERMAL RATING CALCULATION AND DESIGN

OF IMPROVED FAN FOR H2-200 TYPE GEAR BOX

Customer: M/s Greaves Ltd., Pune

MULTIFACET TECHNICAL CENTRE

# 33, SVK Layout, West of Chord Road,
BANGALORE 560 079.
Tel.: 3225394, Tel/Fax: 3224006
E-mail: multifacet@vsnl.net

REPORT No :
Date :

0181

Jun 2003

PREPARED BY:

Murali K.S
Jaiprathap N.S

APPROVED BY:

B.V.Nagendrakumar

THERMAL RATING CALCULATION AND DESIGN OF IMPROVED FAN

FOR H2-200 TYPE GEAR BOX
Abstract:
This report summarises the estimation of Thermal rating of H2 type foot mounted
gearbox and design of improved fan to maximize the heat dissipation and hence
thermal rating. Based on the study of literatures a procedure for estimation of the
thermal rating was established. In order to validate the procedure thermal ratings of
four sizes of gear box viz H2-180, H2-200, H2-225, H2-250 were calculated and
compared with the values given in Catalogue. The performance of the existing and
improved fan was also compared.
List of symbols:
Q=
=
T.R =
hoia =
hoiw =
hnv =
hnh =
hnc =
hfc =
hr =
A =
Anc =
Afc =
T =
X=
Y=
Z=
t =
=
=
K=
k=
Gr =
Nu =
Pr =
g=
=
=
d=
Vf =
fk =

Heat generation in Gear Box (kW)

efficiency of Gear box
Thermal Rating of Gear Box (kW)
Heat transfer co-efficient of oil to ambient air (kW/m2K)
Heat transfer co-efficient of oil to inner surface of Gear Box (kW/m 2K)
Convective heat transfer co-efficient of air for vertical plates
(Natural Convection) (kW/m2K)
Convective heat transfer co-efficient of air for Horizontal plates
(Natural Convection) (kW/m2K)
Convective heat transfer co-efficient of air (Natural Convection) (kW/m 2K)
Convective heat transfer co-efficient of air (Forced Convection) (kW/m 2K)
Heat transfer co-efficient of air (Radiation) (kW/m2K)
Total surface area of Gear box (m2)
Total surface area of under natural convection (m 2)
Total surface area of Gear box under fan cooling (m 2)
Rise in oil temperature (K)
Length of Gear Box (m)
Width of Gear Box (m)
Height of Gear Box (m)
Thickness of Gear Box plate (m)
Density of air in kg/mm3
Co-efficient of absolute viscosity (kgs/m)
Thermal conductivity of air (KW/mK)
Thermal conductivity of gear box material (KW/mK)
Grashof No.
Nusselt No.
Prandtl No.
Acceleration due to gravity (m/s2)
Emissivity of Gear Box material
Stefan Boltzmann Constant (W/m2K4)
Diameter of Fan (m)
Peripheral velocity of fan (m/s)
Fan constant
2

CONTENTS
Abstract
List of symbols
Contents
1.0 Introduction
2.0 Analysis procedure
3.0 Performance of existing and improved fans
4.0 Thermal rating with new fan
5.0 Conclusion
6.0 References
1.0 INTRODUCTION
The main objective of this exercise was to enhance the thermal rating of H2-200
gearbox. A systematic study was commissioned to analyse the above problem while
focusing the attention on improving the fan performance, which would help in
increased cooling. In the process of the above analysis, it was found that the thermal
rating calculations form the core of the above study and it was also found that the
methods available are empirical. Therefore, an attempt has been made to
incorporate basic heat transfer equations to estimate the heat dissipation by natural
convection and by fan cooling. To start with it was necessary to correctly define
thermal rating of gearboxes. Because, depending on the definition of thermal
rating, actual thermal rating calculations will have to be made.
Thermal rating of a gearbox depends on the methods of cooling employed. If the
gearbox cools by natural convection then for the same mechanical rating, thermal
rating would be far lower. And by the same logic, by improved methods of heat
dissipation, thermal rating of the given gearbox could be enhanced.
After establishing the methodology for one size of gearbox and comparing it with
catalogue values, the same procedure was adopted for validating the methodology
on different sizes of gearbox and compared with catalogue ratings. Separate
graphical representations have been made for natural convection and fan cooled or
blown gearboxes with comparisons shown for calculated and catalogue figures for
the different models analysed.
The next step was to have a close look at the fan with the idea of redesigning the fan
to increase its performance and hence improve the thermal ratings. After a
preliminary study, it became apparent that
a) the fan impeller will have to be centrifugal radial bladed only and
b) the cowl that is presently in use cannot be disturbed and that, the improved
design for the impeller will have to work within the cowl space.
Obviously, this is a serious constraint for placing a larger size impeller.
Fan performance calculations have been also been included along with
thermal rating improvement calculations. Manufacturing drawing for the
improved impeller is also provided.
Future work would involve, building a gearbox with the improved fan and testing the
performance on a test rig.

2.0 ANALYSIS PROCEDURE

2.1 Assumptions:
1. The mechanical power lost in the gearbox is transformed as heat.
2. Ambient temperature and rise in oil temperature are assumed to be 30C and
65C respectively.
2.2 Definition of Thermal rating

Ref 1

Thermal rating is defined as the maximum power that a Gear Box can transmit for 3
hours with out the oil temperature exceeding 93C when the ambient air temperature
is not exceeding 30C.
2.3 Specification of the existing gear box
Gear box size
Mechanical Rating
Input speed
Speed Ratio
Efficiency

:
:
:
:
:

H2-200
213 KW
1500 RPM
1:5.6
98%

2.4 Heat generation in the Gearbox

Q (1 ) * P

--------------------- 1

Q (1 0.98) * 213 4.26 KW

2.5 Thermal rating of gearbox without fan (Heat dissipation by Natural convection):
Thermal rating of gearbox is given by,
TR

hoia * A * T
(1 )

---------------- 2

Where,
TR = Thermal Rating in KW
h0ia= Over all heat transfer coefficient of oil to ambient air
A = casing area open to the air in m2
T = Rise in oil Temperature in C = 65C

2.5.1 Estimation of over all heat transfer coefficient of oil to air

4

From the Catalogue and drawings the following dimensions are taken

Fig 1. Gearbox casing dimensions

Length of the gear box (X) = 0.68m
Width of gear box (Y)
= 0.31m
Height of gear box (Z)
= 0.45m
Total Surface area (A) = 2[X*Y+Y*Z+Z*X]

-------- 3

A = 2[0.68*0.31+0.31*0.45+0.45*0.68]
= 1.3126 m2
Taking 25% extra area to consider the curvature, cavities etc.,
A = 1.25*1.3126 = 1.641 m2
Properties of air at 30C (Ref 2) are
= 1.165 kg/m3
Pr = 0.701,
k=26.75x10-6 kW/mK
= 16x10-6 m2/s
Cp = 1.005 kJ/kgK = 18.63x10-6 kg/m-s
= 1/T =1/(273+30) = 0.0033 /K
Grashoff No is given by,
Gr

gTL3 2
2

------------------------ 4

a) Convective heat transfer co-efficient

5

i) Vertical plates
L = Z = 0.45m
Gr

9.81 * 0.0033 * 65 * 0.45 3 * 1.165 2

(18.63 x10 6 ) 2

= 0.75 x 109

Gr*Pr = 0.75 x 109 X 0.701 = 0.526x109 < 1 x 109 => laminar flow
Nusselt No. is given by

Nu 0.825

0.387 * (GrPr) 0.167

1 0.437

Pr

------------ 5

0.296

0.5625

Nu 0.825

0.387*( 0.526 x109 )0 .167

1 0.437

0.701

= 103.6

0 .296

0 .5625

Heat Transfer Co-efficient is given by

hnv

Nu * K
L

hnv

103.6 * 26.75x10 -6
= 0.0062 kW/m2K
0.45

----------------------------- 6

ii) Horizontal plates

L = sqrt (X*Y) Ref3
= Sqrt (0.68*0.31) = 0.46m
Gr

9.81 * 0.0033 * 65 * 0.46 3 * 1.165 2

(18.63 x10 6 ) 2

= 0.801 x 109

Gr*Pr = 0.801 x 109 X 0.701 = 0.561x109 < 1 x 109 => laminar flow
Nusselt No. is given by
Nu = 0.15*(GrPr)0.333

------------------------- 7

Nu = 0.15*(0.561x109)0.333
= 123.75
Heat Transfer Co-efficient is given by
6

Nu * K
L
123.75 * 26.75x10 -6

= 0.0072 kW/m2K
0.45

hnh
hnh

The convective heat transfer co-efficient of air is given by

hnv * 1.25 * 2Z ( X Y ) hnh * 1.25 * 2( X * Y )
A
0.0062 * 1.25 * 2 * 0.45 * (0.68 0.31) 0.0072 * 1.25 * 2 * (0.68 * 0.31)
=
1.641
= 0.00652 kW/m2K

hnc

b) Heat transfer co-efficient due to radiation

Heat transfer by radiation is given by
qr = **(T24 T14)

-------------------------- 8

where = Emissivity of gear box material = 1.0 (assumed)

= Stefan Boltzmann constant = 5.669x10-8 W/m2K4
T1 = Initial Temperature of oil in K
= 303K
T2 = Final Temperature of oil in K
= 368K
Substituting the above values in equation 8, we get
qr = 1.0*5.669x10-8 *(3684 3034) = 561.84 W/m2 = 0.562 kW/m2
Heat transfer co-efficient due to radiation is given by
hr = qr/(T2-T1) = 0.562/65 = 0.00865 kW/m2K
The over all heat transfer co-efficient is given by
hoia

1
1
1
t

hoiw hnc hr k

------------------------- 9

Where,
hoiw= heat transfer co-efficient of oil to inner surface of wall
= 0.08 kW/m2K (From table 3.3 of Ref 3)
hnc = Convective heat transfer co-efficient = 0.00652 kW/m2K
hr = Heat transfer co-efficient due to radiation = 0.00865 kW/m 2K
t=

Thickness of gear box plate = 13 mm (Taken from drawing)

7

k=

Thermal conductivity of Gear box material = 56 W/mK

Substituting the above values in equation 9 we get

hoia

1
1
1
13x10 3 = 0.01271 kW/m2K

0.08 0.00652 0.00865 56 x10 3

Substituting the values in equation 2 we get

TR

0.01271 *1.641* 65
= 67.8 kW
(1 0.98)

2.6 Thermal rating of gearbox with fan (Heat dissipation by Forced convection):
(As per the procedure given in Ref3)

Refer to the above fig,

Area under fan cooling is given by,
Af = 2*[X/2*Z] = 2*[0.68/2*0.45] *1.25 = 0.3825 m 2
Area under natural convection (An) = A-Af = 1.641-0.3825 = 1.2585 m2
Fan diameter (d) = 0215m
Peripheral speed of fan (Vf )

dN
* 0.215 * 1500
=
= 16.89 m/s
60
60

Fan factor (fk) = [Vf/1.25]0.6

= [16.89/1.25]0.6
= 4.77

---------------- 10

Heat transfer co-efficient with fan cooling is given by

h fc

f k 0.010 7 x10 5 T
Z 0.15

h fc

4.77 0.010 7 x10 5 * 65

= 0.0782 kW/m2K
0.45 0.15

--------------------- 11

Thermal rating with fan is given by

T.R

h fc

T.R

* A fc h oia * A nc * T
(1 - )

--------------------- 12

0.0782 * 0.3825 0.0134 * 1.2585 * 65

(1 - 0.98)

= 152 kW

2.7 Validation of the procedure

In order to validate the above procedure thermal ratings of few more models were
calculated and compared with the values given in catalogue. The values are
tabulated in the following table:
Sl
No.

Gear Box
model

1
2
3
4

H2-180
H2-200
H2-225
H2-250

Thermal Rating with out Fan

(kW)
Calculated
Catalogue value
55.6
45.7
67.8
82.0
83.3
102.0
102.6
125.0

Thermal Rating with Fan

(kW)
Calculated
Catalogue Value
116.2
127.0
149
153.0
190.6
186.0
245.9
254.0

The values tabulated in the above table are compared graphically as follows:

Thermal Rating of Gear Box without fan

Thermal Rating (KW)

140
H2-250

120

H2-250

H2-225

100

H2-225

H2-200

80

H2-200

60

H2-180
H2-180

40

Calculated
Catalogue

Gear box type

Thermal Rating of Gear Box with fan

H2-250

260

Thermal Rating (KW)

240

H2-250

220
200

H2-225

180

H2-225

H2-200

160
140

H2-180

H2-200

120
100

H2-180
Gear box type

Calculated
Catalogue

3.0 PERFORMANCE OF EXISTING AND IMPROVED FAN

The following table gives the design and comparison of new fan with the existing fan.
From the table it is clear that the airflow in new fan is increased by 23% when
10

compared to the present design. Refer to figs 3 and 4 for manufacturing drawing and
3D model of new fan.
Radial Blade Fan Design
CASES:
INPUT DATA
1. IMPELLER OUTSIDE RADIUS (d2) in mm
2. IMPELLER INSIDE RADIUS (d1)
in mm
3. BLADE WIDTH AT IMPELLER OUTSIDE RADIUS(b2) in mm
4.BLADE WIDTH AT IMPELLER INSIDE RADIUS(b1) in mm
5. N - FAN SPEED IN RPM

Present Design

New Design

215
41.5
11.6
19.7
1500

228
41.5
12.7
22
1500

CALCULATIONS:
PERIPHERAL VELOCITY U2 = (pi x N x d2)/60 m/s
Vm2 = 0.2 x U2 m/s

16.8855625
3.3771125

17.90655
3.58131

VOLUME FLOW
Q = pi x d2 x b2 x Vm2

0.0264601

0.032578418

IMPELLER TOTAL PRESSURE

p = RHO x U2**2 Kfg/m2 RHO , Density of air in Kgf/m3

342.1466651

384.7734395

POWER
P = Q x p in watts

88.81223553

122.97139

m3/s

Performance of Old design v/s New design

1.% increase in Q from old design
2.% increase in Air Power from old design.

23.12280636
38.46221668

Stress Analysis of fan back plate and blades.

INPUT DATA
1.Wb = Weight of Blades in Kg
2.Wbp = Weight of Back Plates in Kg
3. W = Density of material in Kgf/mm^3
4. Impeller inlet diameter d1 in mm
5. Impeller outlet diameter d2 in mm
6. Impeller width at Inlet b1 in mm
7. Impeller width at outlet b2 in mm
8. Fan speed N in rpm

1. Radial Stress
Fr ={wc * Omega^2 / 8*g}* {(pis+3)(r2 - r1)^2} in Kgf/mm^2
Wbe = Wb/2

11

0.207
1.554
8000
41.5
215
19.7
11.6
1500

0.282
1.77
8000
41.5
228
22
12.7
1500

Present Design
0.1035

New Design
0.141

wc = W * {(Wbp+ Wbe)/Wbp}
where ,
wc = Corrected weight Density in Kgf/m^3
Wbe = Effective Blade weight Wb/2 in Kgs.
W = Density of material in Kgf/m^3
Omega = 2 * pi * N / 60 rads/s
pis = poision ratio 0.3
g = accelration due to gravity 9.81 m/s^2
r1 = d1/2 in M
r2 = d2/2 in M
omega^2
(r2-r1)^2
Therefore radial stress Fr in Kgf/mm^2
2. Hoop Stress
Fh = {wc*Omega^2/4*g}*{(pis+3)r2^2+(1-pis)r1^2} in Kgf/mm^2
3. Bending Stress in Blade

8532.818533
157.075
0.3
9.81
0.02075
0.1075
24672.55563
0.007525563
0.066619376

8637.288136
157.075
0.3
9.81
0.02075
0.114
24672.55563
0.008695563
0.077919144

0.206218367

0.23454576

Input data at Impeller inlet

r = r1 in mm
t in mm
b1 in mm
Fb in Kgf/mm^2

20.75
3
25
0.043489257

20.75
3
25
0.043489257

Input data at Impeller Output.

r = r2 in mm
t in mm
b1 in mm
Fb in Kgf/mm^2

107.5
3
11.6
0.048507435

114
3
12.7
0.061658955

SG600/3
3.3
3.3

3.3
3.3

Fb =

b^2*W*r*Omega^2
--------------------------2*t*g
Where,
Fb = Bending Stress in baldes ,Kgf/mm2
b = width of blade at inlet and outlet in mm
W = weight density of the material in Kg/m3
r = radius of impeller at inlet and outlet in mm
Omega = angular velocity in rads/s
t = thickness of blade in mm
g = acceleration due to gravity.

Material :
1.Allowable Stress for alternating load in Bending , ab in Kgf/mm2
2.Allowable stress for alternating stress in tension, at in Kgf/mm2
Conclusion :
1.Fh,Fr is less than allowable stress hence designs is safe.
2.Fb is also less than allowable stress hence designs is safe.

12

13

4.0 THERMAL RATING WITH NEW FAN

14

From the comparison of the existing and new fan, we have the following data
Existing fan
i) Fan Dia (m)
ii) Flow ,Q (m3/s)
iii) Speed (RPM)

New Fan

0.215
0.020
1500

0.228
0.0325
1500

Equivalent diameter of fan :

From fan laws we have
i.e

Flow diameter3
Q1 d13
------------- 13
Q2 d23
------------- 14

(For existing fan)

(For new fan)

Dividing eqn 13 by eqn 14, we get

3

Q1 d 1

Q2 d 23

=> d 2 3

d2 3

Q2
X d 1 ------------- 15
Q1
0.0325
X 0.215 = 0.232 m > actual dia of new fan
0.026

Area under fan cooling is increased by factor = (d 2/d1)2 = (0.232/0.215)2 = 1.164

Area under fan cooling with new fan
Afc
Area under Natural convection

Anc

= 1.164 * Area with existing fan

= 1.164*0.3825
= 0.4454 m2
= A Afc = 1.641 0.4454 = 1.1956 m2

Repeating the procedure given in section 2.6, we get

Thermal rating of Gear Box with new fan = 168 kW
5.0 CONCLUSION
1. This report represents the results of a systematic study of the problem of
improving the heat dissipation from helical gearboxes.
2. We observe that Thermal rating predictions for the case of gear box with out fan
cooling show departure from catalogue figures. Whereas for the case of fan
cooled gearbox the mathematical predictions show good agreement with
catalogue values. The reasons for this will have to be determined based on the
proposed experimental study.
3. Manufacturing drawing for the improved fan has been provided. As per theoretical
predictions, we expect the improvement in the Thermal rating to an extent of 10%.
The actual improvement in the thermal rating of H2-200 gearbox will have to be
established on the test rig itself.
6.0 REFERENCES
15

1. Darle W.Dudley Handbook of Practical Gear Design

McGraw-Hill Book Company
2. C.P.KOTHANDARAMAN and S.SUBRAMANYAN HEAT AND MASS
TRANSFER DATA BOOK
Fourth Edition, Wiley Eastern Limited
3. Dr.T.H Frost HEAT DISSIPATION FROM GEAR BOXES
Data item submission (008) to the British Gear Association
4. WILLIAM C. OSBORNE FANS
First Edition, PERGAMON PRESS LTD

16