Modeling and Analysis of Tube Axial Flow Fan by Comparison of Material Used and Changing the Number of Blades
A.Mahesh babu1, Dr.V.V.R.L.S.Gangadhar2, Prof.A.Chandra Shekar Reddy3
1PG Scholar, Department of Mechanical Engineering, Holy Mary institute of engineering and Technology, JNTU Hyderabad, INDIA.
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2Professor & Principal, Department of Mechanical Engineering, Holy Mary institute of engineering and Technology, JNTU Hyderabad, INDIA.
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3 Professor &, Head of the Mechanical Department, Holy Mary institute of engineering and Technology, JNTU Hyderabad, INDIA.
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ABSTRACT:The performance of the axial flow fans depends on design of the blades and materials used. In this axial flow fans The air moves parallel to the axis of rotation. Axial flow fans are generally used in mines, tunnels, underground transportation, and industrial facilities for air conditioning and ventilation purposes. In this paper, The 3D modeling software pro/engineer is used to design and modeling of tube-axial flow fan. The numbers of blades are used in the industry 10, in this thesis the number of blades are changed to 8 and 12.The % flow calculations. Analysis is done in fine element analysis ANSYS.The design has to be changed to increase efficiency of the fan by comparing the materials aluminum alloy, mild steel and S-Glass.
Keywords: Materials, axial flow fan, fan efficiency, axial velocity, ANSYS.
I.INTRODUCTION
The axial-flow fan has blades that force air to move parallel to the shaft about which the blades rotate. In an axial-flow fan, with the runner and guide vanes in a cylindrical housing, air passes through the runner essentially without changing its distance from the axis of rotation. There is no centrifugal effect. Guide, or stator, vanes serve to smooth the airflow and improve efficiency. In general, an axial-flow fan is suitable for a relatively large rate of flow with a relatively small pressure gain, and a centrifugal fan for a small rate of flow and a large pressure gain.
II.DIFFERENCE BETWEEN FANS BLOWERS AND COMPRESSORS
Axial fans, blowers and compressors are all equipment’s that move air. They are differentiated by the method they use for moving air and by the pressure rise they can supply. The American Society of Mechanical Engineers (ASME) uses specific ratio that is the ratio of discharge pressure to suction pressure to classify the air moving equipment’s. The range of specific pressure is given in Table1:
Equipment / Specific Ratio / Pressure Rise (Pascal)Fans / < 1.11 / < 11108
Blowers / 1.11–1.20 / 11108– 20201
Compressors / > 1.20 / > 20201
III.AXIAL FAN CONTROL
The most efficient way to mechanically control the output of an axial flow fan is to vary the blade pitch. There are generally three options in this regard:
- Individual adjustment of each blade.
- Simultaneous adjustment of all blades while the fan is stationary using a single point activated mechanism. This system is relatively unusual.
- On line actuation of the blade pitch using a special purpose hydraulic actuator. This allows the fan output to be modulated when the fan is running to suit load demands.
IV.ADVANTAGES
- Higher efficiency suitable for any specific application.
- Reduced overall weight of the fan, thereby extending the life of mechanical drive systems such as motors, gearboxes, bearings etc.
- Low power consumption resulting in appreciable energy savings as compared to existing metallic fans.
- Lower flow noise and mechanical noise levels compared to the conventional metallic fans.
- Longer life of fans due to improved mechanical strength.
- Excellent corrosion & erosion resistance and fire retardance.
V.TYPES OF AXIAL FLOW FAN
The types of axial fans can be classified as following groups. They are propeller fans, tube axial fans, vane axial fans. By use of multistage axial fans, it is possible to have higher pressure rise with the same volumetric flow rate.
A)PROPELLER FANS :Propeller fans are used for high flow rates with little pressure rise.Generally, they are not combined with extensive ducts or systems that require high pressure increase. They are considered to be inexpensive because of relatively simple construction. Their maximum efficiency is achieved near free delivery. They are used for rooftop ventilation or as panels mounted on walls of structures
Fig1:Propeller fan
B)TUBE-AXIAL FANS: Tube axial fans are essentially propeller fans placed inside a cylindrical shell, which is about one diameter long generally. Tube axial fans can generate higher pressure rise and operate at better efficiencies than the propeller fans. They are used in ducted HVAC applications. The impeller is usually mounted directly on the motor shaft and the motor, in turn, is mounted on a folded metal base within the housing. In some cases the fans are belt driven with the motor mounted on a bracket outside the housing.
Fig2:Tube axial fan
C)VANE-AXIAL FANS:Vane-axial fans are high efficiency machines that are unmatched in high specific speed (high volume, lower pressure) applications by other fan types. Vane-axial fans have matched downstream stator vanes that convert the tangential component of the velocity leaving the impeller to the axial direction at a higher static pressure and reduced absolute velocity.
Fig3:Vane-axial fan
VI.THEORETICAL CALUCULATIONS
Nb = 8 blade Formulas
1) Fan diameter (Df) = 500mm
Fan radius (rf) = 250mm
Hub diameter (dh) = 262.5mm
Hub radius (rh) = 131.25mm
Tip radius (rt) = 218.75mm
2) hub and tip ratio r = (rh / rt )
r = 0.5714
3) Number of blades (nb=6r/(1-r)
Nb = 8 blade Dimensions
Fig4:. Modeling 8 Blades in Pro-E
4) Blades spacing (xp) = 2πR/ nb
R = fan radius = 250mm
xp = 196.34mm
Fig 5:Dimensions for 8 Blades in Pro-E
5) Blades width = L ≤ 3.4*d/ nb
Where d = hub diameter
nb = no. of blades
L ≤ 3.4*250/8 = 106.25mm
6) Blades length = (Dfan – Dhub)/2
= 125mm
7) Tip speed (ft/min) = D*S*π/12
D = fan diameter in ft (here 1mt=3.28ft)
S = speed in rpm
Assume S= 1000 rpm
Ts=429.35 ft/min
8) Tip clearance = Fan diameter/100
= 500/100 = 5
9) Blade passing frequency
Fb = = 8*1000/60
= 133.33Hz
10)
Where:(N1=8; N2=10)
= 13.79
11) Axial velocity =Va
Axial Velocity = 5.828*10-3 m/sVII.MATERIAL PROPERTIES
A)ALUMINUM 204
Physical Properties
Density / 2.80 g/cc
Mechanical Properties / Metric
Hardness, Brinell / 110
Hardness, Knoop / 138
Hardness, Rockwell A / 44
Tensile Strength, Ultimate / >= 331 MPa
Elongation at Break / >= 8.0 %
Modulus of Elasticity / 71.0 GPa
Poisson’s Ratio / 0.33
Machinability / 90 %
B)MILD STEEL
Physical Properties / MetricDensity / 7.75 - 8.08 g/cc
Mechanical Properties / Metric
Hardness, Brinell / 86.0 - 562
Hardness, Knoop / 103 - 682
Hardness, Rockwell B / 30.0 – 105
Tensile Strength, Ultimate / 250 - 2450 MPa
Compressive Yield Strength / 152 - 1800 MPa
Bulk Modulus / 140 GPa
Poisson’s Ratio / 0.250 - 0.300
Fatigue Strength / 758 - 772 MPa
C)S GLASS FIBER (GFRP)
Physical Properties / MetricDensity / 2.485 - 2.495 g/cc
Mechanical Properties / Metric
Tensile Strength, Ultimate / 521 MPa
@Temperature-190 °C
1725 MPa
@Temperature 540 °C
Elongation at Break / 4.8 %
Modulus of Elasticity / 72.4 GPa
72.3 GPa @Temperature 540 °C
Poisson’s Ratio / 0.20
Shear Modulus / 30.0 GPa
VIII.STATIC ANALYSIS
A)MILD STEEL(8 BLADES)
Fig6: Imported Model from Pro/Engineer for 8 Blades
Element Type: solid 20 nodes 95
Material Properties:
Young’s Modulus (EX) : 213000 N/mm2
Poisson’s Ratio (PRXY) : 0.3
Density : 0.00000808 kg/mm3
Fig7:Meshed Model in Ansys for 8 Blades
Loads :Pressure – 0.000083944 N/mm2
Angular velocity – 0.263444 rad/sec
Solution
Smaolution – Solve – Current LS – ok
Fig8 :Stress model in Ansys for 8 Blades using mild steel
Fig 9: Strain model in Ansys for 8 Blades using mild steel
B)ALUMINUM
Element Type: solid 20 nodes 186
Material Properties:
Young’s Modulus (EX) : 71000 N/mm2
Poisson’s Ratio (PRXY) :0.33
Density : 0.0000028 kg/mm3
Loads
Pressure – 0.000083944 N/mm2
Angular velocity – 0.263444rad/sec
Fig 10: Stress model in Ansys for 8 Blades using Aluminum
Fig11:Strain model in Ansys for 8 Blades using Aluminum
C)S-GLASS
Element Type: solid 20 nodes 186
Material Properties:
Young’s Modulus (EX) :72400 N/mm2
Poisson’s Ratio (PRXY): 0.2
Density : 0.0000026 kg/mm3
Loads
Pressure – 0.000083944 N/mm2
Angular velocity – 0.263444rad/sec
Fig12: Stress model in Ansys for 8 Blades using S-Glass
Fig 13:Strain model in Ansys for 8 Blades using S-Glass
IX.DYNAMIC ANALYSIS
A)MILD STEEL(8BLADES)
Solution
Solution- analysis type –new analysis – select transient.
Solution controls-
Define these boxes
Time at end of load step- 10
Number of sub steps-10
Max. No. of sub steps-10
Min. no. of sub steps-1
Loads
Define load – apply – structural
– Displacement – on areas – select fixed area.
– Pressure – 0.000083944 N/mm2
– Angular velocity – 0.263444 rad/sec
LOAD STEP OPTIONS
Load step options – write LS file-1-ok
Fig14 :Stress model in Ansys for 8 Blades using mild steel
Fig 15: Strain model in Ansys for 8 Blades using mild steel
C)ALUMINUM
Fig16 : Stress model in Ansys for 8 Blades using Aluminum
Fig17:Strain model in Ansys for 8 Blades using Aluminum
D)S GLASS
Fig18 :Stress model in Ansys for 8 Blades using
S-Glass
Fig19 :Strain model in Ansys for 8 Blades using
S-Glass
X.RESULTS
A)WEIGHT OF AXIAL FLOW FANS (Kg)
MILD STEEL / ALUMINUM / S GLASS8 BLADES / 6.91 / 2.39 / 2.223
10 BLADES / 8.80 / 3.42 / 3.12
12 BLADES / 10.90 / 5.80 / 4.92
Table 2:WEIGHT OF AXIAL FLOW FANS (Kg)
B)THEORETICAL CALCULATIONS
8 BLADES / 10 BLADES / 12 BLADES% OF FLOW CHANGE / 13.79 / 0.862 / 0.854
AXIAL VELOCITY mm/s / 65.861 / 36.589 / 23.862
Table 3: THEORETICAL CALCULATIONS
C)STATIC RESULTS
MILD STEEL
8 BLADES / 10 BLADES / 12 BLADESSTRESS (N/mm2) / 36.99 / 36.42 / 34.53
STRAIN / 0.174 E-03 / 0.172E-03 / 0.189 E-03
Table 4: Static Analysis with Mild Steel
ALUMINUM ALLOY 204
8 BLADES / 10 BLADES / 12 BLADESSTRESS (N/mm2) / 12 / 12.59 / 11
STRAIN / 0.18E-03 / 0.17 E-03 / 0.16 E-03
Table 5: Static Analysis with ALUMINUM
S-GLASS
8 BLADES / 10 BLADES / 12 BLADESSTRESS (N/mm2) / 11 / 11.30 / 10.12
STRAIN / 0.162 E-03 / 0.159 E-04 / 0.152 E-03
Table 6:Static Analysis with S-Glass
D)DYNAMIC RESULTS
MILD STEEL
8 BLADES / 10 BLADES / 12 BLADESSTRESS (N/mm2) / 28.89 / 26 / 28.81
STRAIN / 0.99E-04 / 0.148 E-03 / 0.136 E-03
Table 7: Dynamic Analysis with Mild Steel
ALUMINUM
8 BLADES / 10 BLADES / 12 BLADESSTRESS (N/mm2) / 8.12 / 10.34 / 9.87
STRAIN / 0.77 E-05 / 0.148 E-03 / 0.140 E-03
Table 8: Dynamic Analysis with ALUMINUM
S-GLASS
8 BLADES / 10 BLADES / 12 BLADESSTRESS (N/mm2) / 6.26 / 9.6 / 9
STRAIN / 0.387 E-05 / 0.441 E-04 / 0.135 E-04
Table9: Dynamic Analysis with S-Glass
XI.CONCLUSIONS AND FUTURE SCOPE
In this paper, an axial flow fan is designed and modeled in 3D modeling software Pro/Engineer(creo). Present used axial flow fan in the taken application has 10 blades, in this thesis the number of blades are changed to 12 and 8. Theoretical calculations are done to determine the blade dimensions, % flow change, fan efficiency and axial velocity of fan when number of blades is taken as 10, 12 and 8.By observing the theoretical calculations, axial velocity and % of flow change is more when 8 blades are used. The weight of the fan when 12 blades is increased thereby reducing its efficiency.Present used material for fan is Mild Steel, which has more weight. By replacing it with Aluminum and S Glass epoxy, the weight is reduced thereby increasing its efficiency. By using composite material S Glass, the weight is less than Aluminum alloy.Structural and Dynamic analysis is to done on the fan by changing the materials Mild Steel, Aluminum , and S Glass. Analysis is done in finite element analysis ANSYS.By observing the analysis results, for all materials, the analyzed stress values are less than their respective yield stress values, so using all the three materials is safe under given load conditions. The strength of the composite material S Glass is more than that of other 2 materials Mild Steel and Aluminum. By observing the analysis results, the displacement and stress values are less when 8 blades are used.So we can conclude that using composite material S Glass and using 8 blades is better.
FUTURE SCOPE
Here in the paper we can change the number of blades, blade angle, materials, Design of Hub and also casing for fans with respective pressure, power, flow rate & material properties.
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