WindTunnelDesign PDF
WindTunnelDesign PDF
net/publication/277300480
CITATIONS READS
7 1,128
3 authors, including:
All content following this page was uploaded by Kashif Javed on 27 May 2015.
Kashif Javed1
1
Assistant Professor, Department of Mechanical, Mazhar Ali2
2
Mechatronics & Manufacturing Engineering Lecturer, Department of Mechanical Engineering,
University of Engineering & Technology, KSK Campus University of Lahore, Pakistan
Lahore, Pakistan Student, Skolkovo institute of Science & Technology
[email protected] (MIT collaboration), Moscow, Russia
[email protected] [email protected]
[email protected] [email protected]
287
Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
covers detailed analysis on all the parts of wind tunnel walls of a contraction of given size and shape using a three-
including diffuser, test section, fan & instrumentation; however dimensional numerical panel method. [7] In 1986 Jonathan H.
attention has been focused on contraction cone designing (2D) Watmuff described the analytical methods of contraction cone
in major using CFD modeling which was subsequently design for subsonic wind tunnels. [8] For design of Laboratory
authenticated through experimentation after its construction. wind tunnels that commonly have velocity less than 50m/s,
The 2D design of contraction cone was carried out using 6th Daniel Brassard introduced a special five degree polynomial
degree polynomial wall profile with a square working section. equation for the design of contraction cone profile followed by
the condition that wall profile was having zero first and second
2. Literature Review order derivatives, further, inlet and outlet profile radii roughly
Wind tunnel is an essential tool in engineering, both for model proportional to the area. The result was hoped to be the most
tests and basic research. Based upon the practical utilization of favorable combination of flow uniformity, thin boundary
this tool, a lot of work has been done in its designing. [1] The layers, and negligible losses. [9] J.E. Sargison, G.J. Walker and
definition of a wind tunnel as given by Pankhurst and Holder R. Rossi published his research which describes the design of a
(1952), is, “A device for producing a moving airstream for 2D contraction cone with 6th degree polynomial wall profile
experimental purposes”. [2] The first real scientific for a wind tunnel with a square test section. The objective was
investigation started into the fledgling field of aeronautics, to design low speed subsonic wind tunnel with uniformity of
scientists hoping to achieve heavier than air flight soon realized flow in the working section through CFD modeling with the
that they would need to understand airflow dynamics about an variation of inflection point and inlet curvature. [10, 11, 12, 3]
airfoil in order to design a practical wing. Until the early 1700s, For designing low speed subsonic wind tunnel contraction with
natural wind sources such as high ridges and the mouths of Ma<0.3 using a 6th degree polynomial equation,
caves were used for early testing, so-called whirling arm incompressible and adiabatic flow conditions can be
apparatus. Benjamin Robins is credited as being the first to use considered.
a whirling arm for aeronautical study. Dissatisfaction with the
whirling arms led Frank H. Wenham to design and built a
twelve foot long blower tunnel with a steam powered fan. Sir 3. Current Reserch
Hiram Maxim also put his efforts to construct a wind tunnel
with a three-foot diameter and twice the size of Wenham’s. [3] 3.1 Design Features:
The Wright brothers also made extensive use of a wind tunnel This section covers discussion and selection of all the features
during the development of their third flyer after their first two of wind tunnel on the basis of which the contraction cone was
failed to meet their expectations and so built their own six foot designed.
wind tunnel. Since the 1930s, when the strong effect of free
stream turbulence on the shear layers became apparent, 3.1.1. Test Section:
emphasis has been laid on wind tunnels with low levels of The design of wind tunnel is based upon overall dimensions
turbulence and unsteadiness. [4] A generalization of the Tsien and parameters of the test section. Initially several parameters
method of contraction-cone design was described in 1972 by selected for test section but complexity in design and overall
Raymond L. Barger and John T. Bowen. The design velocity costing reduced these parameters in certain limits that enabled
distribution was expressed in such a form that the required to create a simplified design and to keep an overall length of
high-order derivatives can be obtained by recursion. This wind tunnel in a range of 3 to 4 meter. A Square cross section
method was applicable to the design of diffusers and is selected for the test section (Fig-1) with following
converging-diverging ducts as well as contraction cones.[5] dimensions and parameters.
Since the 1930s, when the strong effect of free stream Mach no = 0.1
turbulence on the shear layers became apparent, emphasis has
been laid on wind tunnels with low levels of turbulence and Desired maximum velocity = V = 35 m/s
unsteadiness. Consequently most of high performance wind Cross section = 180 mm × 180 mm
tunnels were designed as closed type to ensure a controlled
return flow. It is possible with care to achieve high Length of Test Section = 400 mm
performance from an open wind tunnel, thus saving space and
construction cost. A research on the whole design of the low
speed subsonic wind tunnel was conducted by R.D. Mehta and
P. Bradshaw. That not only covers design information but they
also covers selection information about the essential parts of
the wind tunnel. [6] In 1980’s researchers and scientist began
to develop more accurate designs for the development of 2D
and 3D- contraction cones for low speed wind tunnels. An
adaptive design procedure was introduced by James H. Bell
and Rabindra D. Mehta .This method proceeded by computing
the potential flow field and pressure distributions along the
288
Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
Fig.1. 3D-Model of Test Section ratio, and diffuser angle, wall contour and diffuser cross-
3.1.2. Fan Selection sectional shapes. Other parameters like initial conditions,
In order to select a proper size of fan, very simple procedure boundary layer control methods and presence of separation
was followed. Since the area of test section selected was “180 could also affect the flow thus making it very difficult to
mm x 180 mm” or “0.36 sq. ft” and the velocity of air was “35 predict. Almost all the knowledge acquires about the diffuser is
m/sec” or “117 ft/sec” so firstly, the volume flow rate of air at empirical [5, 6]. The length of diffuser section was calculated
test section was determined by the following equation. by size of fan, which was selected to be 15” in diameter. A
Q=vxA square piece was designed and square portion turned out to be
= 117 (ft/sec) x 0.36 (sq. ft) 450 x 450 mm. This became the dimensions of the end of the
= 42.12 cubic ft/sec = 2527.2 CFM diffuser section. The diffusion angle was kept 6 degrees and
ended up being 3 degrees on each side. This calculation made
[3, 10, 11, 12] The above equation was used after assuming the diffuser section 1.5 m long (Fig-3).
the incompressible flow of air in test section due to low “Mach
number” (i.e. Ma < 0.3) [3, 10, 11, & 12]. The size of Fan was
based on desired CFM output. A fan was chosen with “15
inches” diameter and 1.5 hp motor which could move 3500
cubic feet of air per minute. This value was greater than the
desired CFM output i.e. 2527.2 CFM. The fan was in circular
metal frame with a flange of heavy gauge sheet metal at the
exhaust side. The frame houses a direct drive motor assembly
attached to fan hub and secured with a set screw. The fan itself
had seven cambered blades, also made from sheet metal, and
the whole unit was rated for an output of 3500 CFM with
variable output and following specifications in general.
Fig.3. 3D-Model of Diffuser
A control box with a pull chain control drives the fan motor
between the off position and a low and high speed setting. This y = ax^6 + bx^5 + cx^4 + dx^3 + ex^2 + fx + g……(A)
limited the range of possible experimental velocities, so the The location of inflection point and lengths were varied for
power cable was connected to a variable output AC power contraction cone for design optimization through CFD
supply with a maximum output of 440 volts. This Variable AC Analysis. The optimization was based on attaining the
power supply allowed a much wider operating range, though following results
performance suffered somewhat at extreme low or high
velocities which were not taken during the analysis. A quick, Flow uniformity at the test section mid –plane
back-of-the-envelope calculation predicted top centerline
Prevention of separation in the contraction cone
velocities in the neighborhood of about 35 m/s, or close to this
value. Of course, this calculation was incredibly optimistic as Minimizing the boundary layer thickness at entrance
the power losses due to honeycomb, screens, and contraction to the test section.[5]
were completely neglected.
The contraction ratio was selected as 7 (6 to 9 are normally
3.1.3. Diffuser: used), for low speed wind tunnels as recommended by Mehta
Diffuser is an essential component of wind tunnel. It served [5]. The parameters that were kept unchanged are contraction
dual functions in this project, besides of reducing the exhaust ratio (i.e. 7), inlet area (i.e. 477 ×477 mm^2) and exit area
speed and hence reducing cost, it also served as a square to (i.e.180×180 mm^2) of the contraction cone. The coordinate
circular transition piece connecting the test section exit with the system for the contraction profile is defined by the origin
drive section. [5, 6] It has been determined that the flow present at the centre line of tunnel at inlet plane. Further, x-
through diffuser depends upon its geometry defined by area coordinate increases downstream and y coordinate defines the
289
Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
contraction profile and z is in the span-wise direction downstream the contraction cone as near as possible to the test
section [9]. Large contraction ratios and short contraction
lengths are generally more desirable as they reduce the power
loss across the screens and the thickness of boundary layers.
Further, for economical design, we need smaller length of
contraction cone for the required velocity (i.e. 35 m/sec) due
to lesser material and manufacturing cost.
The proper selection of contraction cone profile for wind tunnel
was decided on the basis of computer based modeling and
simulation tools. In this method, after deriving equations
1- For inflection point (i/L) =0.4 (case#1, 2, 3 & 4)
Lengths: 0.5, 0.75, 1 & 1.25 (meters)
Fig 4: 3D-Model of Contraction cone
TABLE.1.1. Mathematical models of different contraction cone profiles
4. Mathematical Model Mathematical Model
6 5 4 3
Equation (A) has 7 constants (a, b, c, d, e, f, g). Five of these Y=95.05242X -171.12898X +106.97264X -23.77403X +0.14855
6 5 4 3
are specified by the height at inlet and outlet, zero slopes at Y=95.05242X -171.12898X +106.97264X -23.77403X +0.14855
6 5 4 3
inlet and outlet as well as zero curvature at outlet. This leaves Y=1.48519X -5.34778X +6.68579X -2.97175X +0.14855
6 5 4 3
two parameters available for optimization. [9] These are Y=0.38933X -1.75236X +2.7385X -1.52154X +0.14855
specified by the inlet curvature (α) and the axial position of the
point of inflection relative to the contraction length [9]. The 2- For inflection point (i/L) =0.5 (case# 5, 6, 7 & 8)
“7” conditions defining the cone profile are given as. Lengths: 0.5, 0.75, 1 & 1.25 (meters)
(1) Y(x=0) =h , (2) Y’(x=0) =0, (3) Y’’(x=0)= α=0
TABLE.1.2. Mathematical models of different contraction cone profiles
(4) Y’’(x=i) =0, (5) Y(x=l) =0, (6) Y’’(x=l) =0, Mathematical Model
6 5 4 3
(7)Y’(x=l) =0 Y=-0.029X -28.48861X +35.64187X -11.88356X +0.14855
6 5 4 3
Y=-0.00255X -3.75159X +7.04037X -3.52105X +0.14855
Where h = inlet half height – exit half height. 6 5 4 3
Y=-0.00045X -0.89027X +2.22762X -1.48545X +0.14855
6 5 4 3
Y= =-0.00012X -0.29172X +0.91243X -0.76055X +0.14855
290
Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
for different inflection points and lengths, these profiles were required in order to allow the simulation to create an
analyzed using CFD technique in ANSYS FLOTRAN CFD approximate solution to the Navier-Stokes equation.
tool for optimizing the design for laminar flow in the test The following strategy was adopted in order to create mesh for
section while avoiding flow separation, boundary layer growth the geometric model of contraction cone and test section
and also accounting cost factor. The method has been together. A basic criterion for division of areas was taken to be
explained below. the same for all the twelve profiles. Fig-10. Shows mesh
generation for selected profile only (i.e. Case # 11).
4.1.1. Geometric Modeling
Geometrical modeling for contraction cone profile and 1. Transverse (Y) Direction
computer based simulations were performed in “ANSYS 2. Inlet region , flow direction (X)
Flotran CFD Package”. Flotran CFD was given preference in 3. Outlet region (initial)
the analysis package. Element type selected was “FLUID 141” TABLE.2. MESH DIVISION STRATAGEY
for 2D- CFD analysis. In Geometric modeling, only upper half 40-Divisions-Basic toward Walls -2 space ratio
1
of the contraction cone was modeled due to symmetry around
2 60-Divisions-Basic at inlet Transition 1 space ratio
Y-axis. Total 100 Key points were generated in the Excel using
corresponding 6-degree polynomial equations for Case # 11. 3 48-Divisions-Uniform Spacing -2 space ratio
Firstly these points were plotted in the ANSYS environment
(Fig-7), afterwards, they were connected through spline, thus
representing the upper half portion of the contraction profile
(Fig-8). Contraction cone was extended to include the test
section in order to visualize the fluid flow in the test section as
well.
Fig.7. Plotting Data points for contraction cone (right) Fig.10. Mesh Generation
Fig.8. Lines plotting for selected data points (left)
Computer based Simulations focusing on velocity and
pressure of air were carried out for all the twelve contraction
cone profiles mentioned in table.1.1, 1.2 & 1.3 Velocity
distribution of all the twelve cases discussed in above table
along the middle plane of contraction cone profile after
computation has been shown in Fig-11
291
Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
The simulations of all the twelve profiles have not been shown
due to unavailability of space. Velocity contour plot of
selected profile (i.e. case # 11) shown in Fig.13 and its
comparison with three others (i.e. case # 3,7 & 12) closer to
the results of case # 11 has been shown in Fig.15. All of these
simulations were based upon the following boundary
conditions. Boundary condition can be defined in either
preprocessing phase or in solution phase. In boundary
conditions, Degree of Freedom of the body was defined to
confine the flow. Velocity was applied at the inlet while value
of atmospheric pressure (absolute zero) was applied at outlet
of the contraction cone (Fig 12).
Fig.14. Velocity variation along wind tunnel length including contraction cone
& test section
From this activity, It was found that the best result, producing
uniform velocity profile at inlet to the working section, and
preventing separation of the flow within the contraction, was
obtained when the point of inflection was located as far
downstream as possible at a moderate length. Hence reducing
both flow separations within the contraction cone as well as
cost of the tunnel because of the moderate length. Therefore
Fig.12. Applying Boundary Conditions
best suited profile is for case # 11 with following
specifications.
Contraction ratio=
Exit area=
Entrance area =
Inflection point =
Length =
292
Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
293
Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
4.1.2. Wind Tunnel Calibration sections i.e. 0.1 m apart along mid-section of contraction cone
length with computer based simulated values at corresponding
Wind tunnel calibration generally involved drilling holes at points during CFD analysis in ANSYS FLOTRAN.
mid-plane section of contraction cone and construction of Experimental values of velocities were measured indirectly
manometer. In order to measure pressure distribution in the from pressures. Where, pressures were measured by
axial direction of contraction cone, 10 numbers of holes of determining the height of water head in manometer and using
inner diameter 2mm and outer diameter 5mm at a mutual the following relation.
distance of 0.1m (i.e.0.1m, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9
& 1.0m) were drilled at mid-plane section. Pneumatic fittings
were placed afterwards in drilled holes.
After calculating pressures, experimental values of velocities
Construction of manometer involved the following steps. A were obtained from following equation as defined by [16]
wooden board of size 3 x 3 feet was selected and four pieces Kailash Kotwani, Professor S K Sane and Dr. Hemendra Arya
of steel rods as well. Drilling of 10 holes of 1/8 in each piece [16].
of steel rod was carried out. Plastic tubes 20 in numbers and
20 inches lengths were selected. The position of 4 rods was ----------(c)
marked on wooden board and rods were fixed on board by the Where
help of nuts and bolts. Pneumatic fittings were fixed on steel = 1000 kg/mᶟ at 25°C
rods Fig-19. Finally, fixing of plastic tubes in pneumatic
fittings was carried out to construct an inclined manometer as = 1.182 kg/mᶟ at 25°C
shown in Fig-20. Colored water was used in order to visualize The values thus evaluated have been shown in table 3
and calculate pressure distribution. corresponding to different values of “X”.
Fig.21. Wind Tunnel in Assembled form It is evident from the results of pressure that variation in
simulated and experimental values is not more than 2 %. As
5. Experimental Results & Discussions long as the velocity is concerned, the difference is observed
from X = 0 to 0.9 m consequently achieving the desired
In the experimentation of wind tunnel, the design of velocity of about 35 m/sec at X=1.0 m (i.e. contraction cone
contraction cone was validated by comparing experimental outlet/test section).It can be inferred from the results that, the
values of pressure & velocity of air obtained at different most possible reason of this difference is due to software
294
Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
limitation as the simulation resources were limited to 2D 4- Raymond L. Barger and John T. Bowen Langley: “A
analysis of the contraction cone profile for the wind tunnel due GENERALIZED THEORY FOR THE DESIGN OF
CONTRACTION CONES AND OTHER LOW-
SPEED DUCTS”. Research Center Hampton, Va.
23365, Page-1 & 3A; November 1972.
5- R.D. Mehta and P. Bradshaw: “Technical notes of
design for small low speed wind tunnels” Reprinted
from the aeronautical journal of the royal
aeronautical society, Page-1, 445, 446 & 448;
November 1979.
6- Y James H. Bell and Rabindra D. Mehta:
“CONTRACTION DESIGN FOR SMALL LOW-
SPEED WIND TUNNELS”.Page-1 & 2; April 1988.
7- JONATHAN H. WATMUFF: “Wind tunnel
contraction design”. Gas dynamics laboratory,
department of mechanical and aerospace engineering,
Princeton University, Princeton, New Jersey 08544,
U.S.A, Page-1, December 1986.
8- Daniel Brassard: “Transformation of a polynomial
for a contraction wall profile”. Undergraduate
Fig.22. Comparison of Experimental and Simulated values of velocities at mid
working plane student, lakehead university, Ontario, Canada, Page-
1, Feb 24, 2003.
6. Conclusions & Future Aspects 9- J.E. Sargison, G.J. Walker and R. Rossi: “Design and
calibration of a wind tunnel with a two dimensional
Contraction cone design aimed at acquiring uniform and contraction”, Page-1, 2, 3 & 4; December 2004.
steady stream at its outlet section and avoidance of flow 10- Frank M White: “Fluid mechanics” 7th edition, Page-
separation with a desired velocity (i.e. 35 m/sec). 572.
Computational approach along with past research has been 11- Compressible flow Wikipedia.
used to select proper length and inflection point which are http://en.wikipedia.org/wiki/Compressible_flow,
known to be basic parameters for optimizing 2D-design of “April 2010”
contraction cone through velocity contour profile 12- Munson Young okiish: “Fundamentals of fluid
investigation. The CFD analysis of velocity contour profile mechanics” 6th edition, Page-580.
authenticated and allowed the use of sixth order polynomial 13- “A vision in aeronautics” the wind tunnel project
equation for generating 2D-design of contraction cone which white paper.
was further analyzed and proved by experimentation after 14- http://www.grc.nasa.gov/WWW/k-
construction and calibration of wind tunnel. 12/WindTunnel/windtunnel_report.html,”April,
2010”
The main objective of constructing this wind tunnel was to 15- M. Abbaspour & M.N Shojaee: “Innovative approach
carry out experimentation on different types of airfoils in to design a new national low speed wind tunnel”,
laboratory. The current research may be extended to include Department of Mechanical Engineering Sharif
other parameters like flow visualization over test specimens of University of Technology and Graduate School of the
different materials through smoke, installing six force sensors Environment & Energy, Science and Research branch
for measurement of yaw, pitch and roll & automation of tunnel IAU, Tehran, Iran, 10 Dec. 2008.
for data Acquisition 16- Practices Manual for Low Speed wind Tunnel, TA-
7. References 50-250, Aerodynamic Tunnel EDIBON, S.A. c/ San
Jose 11-13, 28921-Alcorcon (Madrid) Espane.
1- WIND TUNNEL WIKIPEDIA 17- Kailash Kotwani, Professor S K Sane and Dr.
http://en.wikipedia.org/wiki/Wind_tunnel, “March, Hemendra Arya: “Wind Tunnel Performance
2010”. Analysis (Measuring Power Requirement) Practical
2- Craig A. Zehrug: “Comparative Analysis of a Low- Training Report”. Center for Aerospace System and
Speed Wind Tunnel Designed for Renewable Energy Design Engineering Department of Aerospace
Applications”. Purdue University Purdue e-Pubs Engineering Indian Institute of Technology, Bombay,
College of Technology Theses and Projects, Page-10, Page-9; August, 2003.
2011.
3- WIND TUNNEL INDEX, NASA“
http://www.grc.nasa.gov/WWW/K-
12/airplane/shortt.html”, “Jan, 2011”.
295
Scientific Cooperations International Workshops on Engineering Branches
8-9 August 2014, Koc University, ISTANBUL/TURKEY
296