World Academy of Science, Engineering and Technology

International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:8, No:11, 2014

Modeling and Simulation of Axial Fan Using CFD

Hemant Kumawat

International Science Index, Aerospace and Mechanical Engineering Vol:8, No:11, 2014 waset.org/Publication/10000214

AbstractAxial flow fans, while incapable of developing high

model the flow passing through an axial fan. The objective

was to determine ways to increase the efficiency.

pressures, they are well suitable for handling large volumes of air at
relatively low pressures. In general, they are low in cost and possess
good efficiency, and can have blades of airfoil shape. Axial flow fans
show good efficiencies, and can operate at high static pressures if
such operation is necessary. Our objective is to model and analyze
the flow through AXIAL FANS using CFD Software and draw
inference from the obtained results, so as to get maximum efficiency.
The performance of an axial fan was simulated using CFD and the
effect of variation of different parameters such as the blade number,
noise level, velocity, temperature and pressure distribution on the
blade surface was studied. This paper aims to present a final 3D CAD
model of axial flow fan. Adapting this model to the available
components in the market, the first optimization was done. After this
step, CFX flow solver is used to do the necessary numerical analyses
on the aerodynamic performance of this model. This analysis results
in a final optimization of the proposed 3D model which is presented
in this article.

KeywordsANSYS CFX, Axial Fan, Computational Fluid

Dynamics (CFD), Optimization.
I.INTRODUCTION

HE axial flow fan is extensively used in many engineering

applications. This type of fan is used in a wide variety of
applications, ranging from small cooling fans for electronics to
the giant fans used in wind tunnels. Axial flow fans are
applied for air conditioning and industrial process
applications. Its adaptability has resulted in implementation
into large scale systems, from industrial dryers to automotive
engine cooling and in-cabin air recirculation systems [1], [2].
The extended use of axial flow fans for fluid movement and
heat transfer has resulted in detailed research into the
performance attributes of many designs. Numerical
investigations have been performed to quantify the
performance of axial fans and their flow characteristics [3].
Axial fans blow air along the axis of the fan, linearly, hence
their name. The axial-flow fans have blades that force air to
move parallel to the shaft about which the blades rotate [4].
With the expressive computer capability and extensive
development in the simulation field, CFD have drawn
attention in recent years. With the help of CFD, the complex
3-D geometries of equipment can now be modeled with only
minor simplifications [5]. CFD models, if created correctly,
can account for the complex flows in equipment. CFD models
for axial fans have been used to evaluate the flow behavior
and characteristics. The models provide sufficiently accurate
predictions over a range of operating conditions, which are not
possible using other methods. In this paper, CFD was used to
Hemant Kumawat is a Mechanical Engineer, from VIT University,
Vellore, Tamil Nadu, India (2014) (phone: +917073195809; e-mail:
[email protected]).

International Scholarly and Scientific Research & Innovation 8(11) 2014

Fig. 1 Axial fan assembly

Axial flow fans, while incapable of developing high

pressures, they are well suitable for handling large volumes of
air at relatively low pressures [6]. In general, they are low in
cost and possess good efficiency, and can have blades of
airfoil shape. The operating principle of axial-flow fans is
simply deflection of air. Flow can be decomposed into two
components: axial velocity and tangential or circumferential
velocity. Axial velocity is the desired velocity since it moves
air from/to the desired spaces and tangential velocity is an
energy loss in axial fans or it can be converted into static
pressure as in case of vane axial fans.
II.

EXPERIMENTATION

The first step is to identify a typical axial flow fan that can
be reproduced as a 3-D CAD Solidworks software
engineering drawing package (Fig. 2).
The 3-D models are then imported into the CFD software,
remodeled into different sections, and refined to generate a
finite volume meshing. This is a crucial step, where details of
the geometrical shape need to be defined precisely. The flow
domain is also created (Fig. 3), and the final meshing of all
components needs to be accurate. Any errors in the drawings
and flow area need to be corrected before continuing.

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International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:8, No:11, 2014

International Science Index, Aerospace and Mechanical Engineering Vol:8, No:11, 2014 waset.org/Publication/10000214

zero pressure at outlet, and variable mass flow rate at inlet.

The residual values of all variables solved are monitored
during the iteration
ion process. This iteration process needs to be
monitored for convergence and repeated if the numerical error
conditions are not satisfied. The final step is to analyze the
output data and present them in the form of velocity
streamline (Fig. 5) and contou
contour plots (Fig. 6).

Fig. 2 Solidworks CAD model of fan

Fig. 4 Simulation parameters

Fig. 3 Computational domain of fan

The second step is to import the files into the

t CFD code
preprocessor, which will solve the flow equations. Here, the
flow fields boundary conditions are set. These include inlet air
mass flow, outlet pressure, fluid properties, and flow domain
characterization, such as moving internal zone and stati
stationary
solid walls. The next step is to set the simulation process as a
3-D
D steady and turbulent problem (Fig. 4).
The simulation is preceded with the CFD code processing
the data, applying the basic theory of fluid mechanics by
balancing the mass continuity
y and momentum equations in
numerical form and thereafter producing numerical
predictions of the flow variables. The problem setup process is
completed by defining the boundary conditions, solver
controls, and convergence monitors. Assuming the flow to be
ideal and dry air at standard atmospheric pressure, the
boundary conditions include fixed wall, moving internal zone,

International Scholarly and Scientific Research & Innovation 8(11) 2014

Fig. 5 Velocity streamline of fan

III.

RESULTS AND DISCUSSION

On post-processing
processing the numerical CFD results, the
observations are presented as velocity streamlines,
temperature contour plots, and static pressu
pressure contour plots.
Optimized design results were then compared with initial
design for temperature contour and velocity streamline and

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World Academy of Science, Engineering and Technology

International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:8, No:11, 2014

International Science Index, Aerospace and Mechanical Engineering Vol:8, No:11, 2014 waset.org/Publication/10000214

presented in the form of contour plots. Results are compiled

separately for initial and optimized designs.

the high temperature melting. Blade life is highly decreased.

Temperature of the output air is also increased. Efficiency
goes down.

ure contour of fan

Fig. 6 Pressure
Fig. 8 Pressure contour of initially designed fan

A. Initial Design
Initially designed fan is having 7 blades. For initially
designed fan, results were compiled for air flowing at a rate of
22 m/s and having the outlet pressure as atmospheric. Fig. 7
shows the turbulence kinetic energy con
contour plot of initially
designed fan.

Fig. 9 Temperature contour of initially designed fan

Fig. 7 Turbulence K.E. contour of initially designed fan

Fig. 8 shows the pressure contour of initially designed axial

fan. By observing the pressure contour, pressure ranges from
negative to positive scale; hence, creating a pressure zone at
the outlet.
Fig. 9 shows the temperature contour of initially designed
axial fan. Variation in temperature occurs because of room
temperature of air and frictional heating. Temperature
variation is not uniform on the blade surfa
surface as seen in the
figure. Color (showing temp contour) is drastically changing.
Sudden change in temperature on the blade surface will lead to
the formation of thermal cracks which can damage the blade.
Moreover, the airfoil design of the blade gets distorted
distor
due to

International Scholarly and Scientific Research & Innovation 8(11) 2014

Fig. 10 Velocity streamline of initially designed fan

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International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:8, No:11, 2014

International Science Index, Aerospace and Mechanical Engineering Vol:8, No:11, 2014 waset.org/Publication/10000214

Fig. 10 shows the velocity streamlines of initially designed

fan. By observing the plot, velocity streamlines are not
uniform over fan wheel which implies that flow is not
uniform. Large variation in velocity
elocity can be seen across the
blade. As we can see from Fig.. 10, the colour of the
streamlines changes drastically as we move across the blade.
Moreover, there is a reduction in velocity at outlet. This non
uniform flow will result in huge noise and acous
acoustic problems
and will decrease the overall efficiency.
B. Optimized Design
Optimized designed fan is having 11 blades. For optimized
designed fan results were compiled for same working
conditions as for the initially designed fan - air flowing at a
rate of 22 m/s and having the outlet pressure as atmospheric.
Fig. 8 illustrates the temperature contour of optimized
designed fan.

Fig. 12 Velocity streamline of optimized designed fan

IV.

Fig. 11 Temperature contour of optimized designed fan

Fig. 11 shows the temperature contour of optimized

designed axial fan. Variation
ation in temperature occurs because of
room temperature of air and frictional heating. Temperature
variation is almost uniform on the blade surface or it is almost
same throughout the blade. This is evident form the same
color pattern of temperature contourr of blade. In this design
there is less chances of formation of thermal cracks. The
design of the fan blade remains unchanged throughout the
working life of fan. Blade life is increased. Temperature of the
output air is same or nearly same as input air. E
Efficiency
increases.
Fig. 12 shows the velocity streamlines of optimized
designed fan. By observing the plot, velocity streamlines are
uniform which implies that flow is uniform. Required
variation in velocity across the blade is achieved. Color of
streamlines
ines is almost same across the blade, i.e., at input and
output. We get the desires output velocity at output according
to the parameters given. As a result of uniform flow, we get
lesser or negligible noise and all acoustic problems are solved
and hence efficiency is increased.

The results from the numerical simulations provided an

insightful understanding of the behavior of fluid flow around
an axial fan with different number of fan blades.
blad Numerical
CFD analysis was performed for both initially designed and
optimized designed axial fan. The numerical CFD results for
optimized design were then compared with initially designed
axial fan. The key and important outcomes of this study are as
follows:
1) The CFD modeling shown in this study proved to be very
helpful in initiating further and more comprehensive
numerical study of the axial fan.
2) CFD results were presented in the form of velocity
streamlines, which provided actual flow characteristics
characteristi of
air around the fan for different number of fan blades.
3) The different parameters like temperature, pressure, fan
noise, and turbulence, were also considered while
performing CFD analysis. The study revealed that a fan
with an optimum number of fan blades
bla
performed well as
compared to the fan with less number of fan blades. In
general, as a compromise between efficiency and cost,
five to twelve blades are good practical solutions. Our
optimized design is having 11 blades.
ACKNOWLEDGEMENT
The author thanks
ks the management of VIT University for
their support and permission to publish this paper. He also
expresses gratitude to all of the faculties and lab assistants
who contributed to the job design, preparation, and execution
of the operation to achieve the results presented in this paper.
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International Scholarly and Scientific Research & Innovation 8(11) 2014

CONCLUSION

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scholar.waset.org/1999.8/10000214

World Academy of Science, Engineering and Technology

International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:8, No:11, 2014

[4]

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[6]

Engineering Research & Technology (IJERT), Vol. 1 Issue 3, May 2012 ISSN: 2278-0181.
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University of Siegen, Paul-Bonatz-Strasse 9-11, 57223 Siegen, Germany.
Park, J., A Sound Method for Fan Modeling, Fluent News, US,
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International Scholarly and Scientific Research & Innovation 8(11) 2014

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