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2900 - Axial Flow Fan Design
2900 - Axial Flow Fan Design
sjvdspuy@sun.ac.za
Today
1. Background
2. Dimensionless numbers
3. Hub-to-tip ratio
4. Velocity diagrams
5. Free vortex velocity distribution
6. Blade element theory
7. Testing of axial flow fans
Howden.com
Axial flow fans
radians
• Specific speed enables us to arrange similar machines in
terms of speed - , flow – and pressure capacity. If we
therefore have the pressure, flow rate and speed, we can get
an indication of machine type and efficiency.
Dimensional Analysis
• Specific speed (Csanady, 1964)
Dimensional Analysis
• Specific diameter:
Determined by
cooling requirements
of heat exchanger
installation
Determined by
efficiency, structural
and noise limitations
on fan installation
Determined by
location of heat
exchanger
installation
Axial flow cooling fan
• Typical fan curves
• Fan static pressure
Axial flow cooling fan
• Typical fan curves
• Fan shaft power
Axial flow cooling fan
• Typical fan curves
• Fan static efficiency
Axial flow cooling fan
• Consider the use of the term fan “static pressure”
There are two terms used for fans, namely fan total pressure and fan
static pressure:
• Design process:
• The most important part is to
start right to finish right.
• The first step is to specify the
hub-to-tip ratio correctly.
• Hub-to-tip ratio selected
based on the method of Van
Niekerk (1958).
Axial flow fan
• Hub-to-tip ratio
• Based on the work of Van Niekerk (1958) with modifications by
Bruneau (1994)
• Calculates total-to-total and total-to-static efficiencies for different
hub-to-tip ratios at design point
• The derivation of this equation is shown in the work of Bruneau
(1994).
• Isolated foil theory is assumed, which requires the blade solidity to
be less than 0.7. If this is not the case, cascade theory has to be
considered.
Axial flow fan
• Vortex design
• The vortex design is by designing on an outlet swirl velocity distribution and
then applying simple radial equilibrium in order to determine the axial
velocity distribution. The SREE is basically a balance of the radial forces
due to curvature of the streamlines, with zero radial flow.
Axial flow fan
• From thermodynamics
Axial flow fan
• Assuming that the stagnation enthalpy and entropy stays constant w. radius
• This last equation gives us the ability to derive an axial velocity distribution
of a swirl distribution is given.
Axial flow fan
• Vortex design
• It should be apparent that the vortex design is multi-
dimensional. The decision for swirl distribution is affected by
many factors.
• The free- vortex distribution gives close to the optimum
efficiency.
• The free vortex distribution might however result in
excessive blade twist.
• At this stage it is required to sub-divide the blade span into a
set number of radial sections.
Axial flow fan
• Example
Axial flow fan
• Blading design
• Once the vortex distribution is fixed, the blading design can be completed.
• The vortex design gives the required velocity triangles downstream of the
blade, at the different radial locations.
• It is advisable to select a base profile for the design at this stage. This can
however be omitted and made part of the design question.
• Isolated airfoil theory is used.
• Blade profile properties (at the different radii) assume the average flow
conditions to prevail over the blade.
Axial flow fan
• Blading design
• The blade loading factor is derived from Dixon by assuming the drag
contribution to be negligible:
• The loading factor therefore gives a balance between the chord length and
blade section lift coefficient required to satisfy the velocity requirements.
• Five factors have to be considered:
» Efficiency – higher speeds and chords lead to higher Re number, giving
higher resistance against stall. Centrifugal load should however be
considered.
» Noise – higher solidity means possible lower running speed, less blades
lead to less noise sources.
» Manufacture - shorter chords lead to easier manufacture.
» Stability – extreme blade setting angles, close to stall should be avoided.
» Cost – less blades
Axial flow fan
• Blading design
• The design solution is therefore to have the minimum number of blades
(cost) at the highest possible speed (efficiency) with the largest
manufacturable chord (manufacturing) far from stall (stability) at the
minimum possible noise. The last requirements is often ignored.
• The chord distribution is therefore selected to be in the order ~1 m. The
number of blades is then manipulated to give Lift coefficient values between
0.5 and 1.0.
• The fan efficiency is then estimated from:
Axial flow fan
• Blading design
• Blade sectional properties can be obtained from published data or XFOIL:
Axial flow fan
• Blading design
• For the efficiency estimation, the losses are given as:
• The drag coefficients are estimated from airfoil profiles that correlate to the
calculated lift coefficient. The blade stagger angle is finaly defined from the
sectional lift curve, as:
Axial flow fan
• Typical results
Axial flow fan testing