DESIGN AND SIMULATION OF CENTRIFUGAL BLOWER USING COMPOSITE MATERIALS

DESIGN AND SIMULATION OF CENTRIFUGAL BLOWER USING COMPOSITE MATERIALS 1 SAI RAGHU VEMURI, 2 P.V VISWANATH 1 PG Scholar, Department of MECH, Vidya Jyothi Institute of Technology, RangaReddy, Telangana, India. 2 Associate Professor, Department of MECH, Vidya Jyothi Institute of Technology, RangaReddy, Telangana, India. Abstract Centrifugal blowers are used in naval applications and motors. The Contemporary blades in Centrifugal Blower used in naval applications are made up of Aluminum or Steel. It is proposed to design a blower using Computer Aided Design (CAD) software with various metal alloys and Non-Metallic composite materials, analyze its strength and deformation using simulation software. In order to evaluate the effectiveness of Metal Alloys and Non-Metallic composites. The present work aim is to change the material and performing the different analysis like Static, Dynamic, Flow Simulation & Cost Analysis to find the best material to decrease the weight and increase its efficiency by using the software SOLID WORKS. Key Words: Centrifugal Blower, Computer Aided Design (CAD), Metal Alloys, Non-Metallic Composite Materials, SOLIDWORKS, Simulation Analysis. I INTRODUCTION them against, dampers and other components which causes the resistance. Centrifugal fans accelerate air radically, changing the direction (typically by 90 ) of the airflow. They are quiet, sturdy, capable, and reliable of operating over a wide range of critical conditions. Centrifugal blowers are constant volume or displacement devices, at a constant fan speed, centrifugal blowers will pump a volume of air constantly irrespective with the constant mass rate. This means that the air velocity in a system is fixed even though mass flow rate through the fan is not. Centrifugal fans are well suited for industrial and traditional purpose. It has a fan wheel composed of a number of fan blades, or ribs, mounted around a hub. The hub actuates on an electric driveshaft that passes through the fan housing. The gas enters from the entrance of the fan wheel, turns 90 and accelerates due to centrifugal force as it flows over the curve of fan blades and exits the fan housing. A centrifugal blower is a mechanical device for moving air or other gases. The terms "blower" and "squirrel cage fan" (because it looks like a hamster wheel) are frequently used as synonyms. Rotating impellers increase the speed of the air blowing from other end. They use the kinetic energy of the rotating blade or impeller to increase the pressure and tends to slightly decrease velocity of the air/gas stream which in turn moves Typical Centrifugal blower

Types of blowers Blowers can achieve much higher pressures than fans and also produce negative pressures for industrial vacuum systems. Main types of blowers,which are described below. a) Centrifugal blower b) Positive-Displacement Blower Blower efficiency and performance: Blower efficiency is the ratio between the power transferred to the airstream and the power delivered by the motor to the Blower. The power of the air flow is the product of the pressure and the flow, corrected for unit consistency. Another term for efficiency that is often used with fans is static efficiency, which uses static pressure instead of total pressure in estimating the efficiency. When evaluating fan performance, it is important to know which efficiency term is being used. The Blower efficiency depends on the type of fan and impeller. As the flow rate increases, the efficiency increases to certain height ( peak efficiency ) and then decreases with further increasing flow rate. The peak efficiency ranges for different types of centrifugal and axial fans are given Efficiency of Various Fans Centrifugal Blower working principle Centrifugal force is used as a main principle for the kinetic energy produced by the impeller to the air/gas which is used as a fluent. By this principle the gas enters in to the impeller and thrown off by creating kinetic energy at the exit. As a result, the pressure is measured in terms of kinetic energy because of casting and duct which offers system resistance. The gas is then guided to the exit via outlet ducts. The gas pressure in the middle region of the impellers decreases after it is thrown off. The cycle repeats when the gas from the impeller eye rushes and therefore the same volume of gas can be continuously transferred. Velocity triangle: A diagram called a velocity triangle helps us in determining the flow geometry at the entry and exit of a blade. A minimum number of data are required to draw a velocity triangle at a point on blade. Some component of velocity varies at different point on the blade due to changes in the direction of flow. Hence an infinite number of velocity triangles are possible for a given blade. In order to describe the flow using only two velocity triangles we define mean values of velocity and their direction. Velocity triangle of any turbo machine has three components as shown.

(c) Computational fluid dynamic (CFD) Analysis. (d) (e) Cost analysis. Weight Analysis. The modeling of the impeller and the above mentioned analyses will be done by Solidworks software. In addition to that a method to fabricate the Impeller with E-glass/Epoxy is studied for realization of product. LITERATURE REVIEW Velocity triangle for forward facing blade These velocities are related by the triangle law of vector addition: V= U+V r Where U= Blade velocity Vr= Relative Velocity V= Absolute velocity Scope and objective of present work: The Contemporary blades in Centrifugal Blower used in naval applications are made up of Aluminum or Steel. The objective of present work is to design a Impeller of a Centrifugal blower with four materials, which are: (a) Aluminum Alloy 1060 (b) Graphite (c) Titanium (d) E-glass/Epoxy To analyze which material made impeller gives better results in terms weight, Output pressure, Out-put velocity, Breaking point, efficiency and cost-friendly. These results can be obtained by performing the following analysis on each material type. (Dr). M.L Kulkarni has developed strategy and design procedure for blower which is expected to bring down the lead time during designing through the Reverse Engineering approach. The different dimensions & geometry of parts of the existing blower were found out by obtaining the Cartesian coordinates of various identified points. Thereafter the required profile and models were developed using this data with the help of CATIA V5 modeler. The Suction condition and other related data s such as inlet & outlet diameter, inlet & outlet vane angles & vane width at the inlet and outlet were used to calculate specific data s such as Absolute velocity of the jet, velocity at the inlet and outlet, whirl velocity at outlet and exit angle of jet at the vane. The project also covers areas of Geometric Analysis, Fluid Dynamics and Concept of Curve Generation THEORITICAL CALCULATION: Attempts are made to address this issue through considering the input values as below. Sl. No. Parameters Values 1 θ 40 o 2 ф 50 o 3 N 1300 rpm 4 b 1 53.4 mm 5 b 2 58.4 mm 6 r 1 16.25 mm 7 r 2 295 mm 8 R 381 mm 9 Blade curve Parabolic (a) (b) Static Analysis. Dynamic Analysis. u = r ω

u = r ω tan θ = v 1 /u 1, v 1 = v f1 Q = 2πr 1 b 1 v 1 V f2 = Q/2πr 2 b 2 By using the above mentioned equations and input values, the following values were calculated: Angular velocity ω = 136.13 rad/sec Vane velocity at inlet u 1 = 2.212 m/s Vane velocity at outlet u 2 = 29.4 m/s Velocity of flow at inlet v f1 = v 1 =292 m/s Velocity of flow at outlet v f2 = 26.17 m/s Discharge Q = 1.592 m/s Whirl velocity at outlet V w2 = 12.47 MODELLING AND SIMULATION: ANALYSIS & DATA COLLECTION: Material properties: Static Analysis on impeller of Al Alloy 1060: Model with volumetric properties of AA1060 Applying Loads and fixtures Applying Loads and Fixtures on impeller of AA1060

Meshing: INTERNATIONAL JOURNAL Mesh information of AA1060 Total deformation table of AA1060 Dynamic Analysis Meshed model of AA 1060 Static stress, Strain and total deformation values Dynamic Analysis on impeller of Al Alloy 1060: Applying Loads and fixtures Static stress result table of AA1060 Applying Loads and Fixtures on impeller of Al Alloy 1060 Dynamic Stress, Total deformation and Mass participation: Strain result of AA 1060 Dynamic stress result table of Al Alloy 1060

Total deformation table of Al Alloy 1060 Pressure Counters Mass participation (normalized) table of Al Alloy 1060 Flow simulation Applied Boundary Conditions Velocity Counters Pressure and velocity distribution at blades Inlet Velocity -14m\s Pressure distribution at Blades Angular velocity of impeller up to 13000 rpm Pressure and velocity counters Velocity distribution at Blades

Pressure and velocity flow trajectories: Load applied on each material was 1500N Pressure flow trajectories Minimum stress (N/M 2 ) Vs. Material Velocity flow trajectories As we observe the pressure counters, it is shown that the pressure is slightly decreased at the outlet due to the peek efficiency reached by the flow rate. Maximum stress (N/M 2 ) Vs. Material Cost analysis: RESULTS, DISCUSSIONS AND CONCLUSIONS Static Stress analysis results Dynamic analysis Results Deformation (Mm) Vs. Material Load applied on each material was 1500N

Cost Analysis Result: Minimum stress (N/M 2 ) Vs. Material Material Cost Maximum stress (N/M 2 ) Vs. Material Manufacturing Costs Total Costs Deformation (Mm) Vs. Material Flow Analysis Result It is observed that the Velocity at out let is decreased compared to inlet and Pressure increases at the outlet, due to the peek effect.

Weight Analysis Result: [2] S R Shah, S V Jain and V J Lakhera, CFD based flow analysis of centrifugal pump, Proceedings of the 37th National & 4th International Conference on Fluid Mechanics and Fluid Power, IIT Madras, Chennai, 2010. [3] P.Usha Shri ans C.Syamsundar, computational analysis on performance of a centrifugal pump impeller, Proceedings of the 37th National & 4th International Conference on Fluid Mechanics and Fluid Power, IIT Madras, Chennai, 2010. Weight Density Vs. Material CONCLUSION Modeling and simulation of centrifugal blower fan has done using Solid Works software. After observing the static and dynamic analysis values we can conclude that e-epoxy has the better stress bearing capacity compared with the other materials except titanium deformation values by showing its better strength values to the applied loads. During Flow simulation at impeller output velocity is decreased compared to inlet velocity, where as output pressure is increased compared to inlet pressure. By using cost analysis methods, the material cost of each metal is noted shown in graphs and we can observe that cost of e-epoxy is slightly more than aluminum and this can be reduced in long run of manufacturing. E-glass/Epoxy material is non metallic component so, the chattering noise will be low compared to other materials during the functioning process. For manufacturing the centrifugal blower impeller we can proceed with Epoxy/E-glass material because it has high stress bearing capacity and reasonable manufacturing cost. FUTURE SCOPE: CFD analysis of different types of impellers with change of RPM The composition of e-epoxy can be changed with optimum composition of the resin and hardeners, So that the maximum stress acting on the material may reduce which proportionally decreases the deformation. REFERENCES [1] S.Rajendran and Dr.K.Purushothaman, Analysis of a centrifugal pump impeller using ANSYS-CFX, International Journal of Engineering Research & Technology, Vol. 1, Issue 3, 2012. [4] E.C. Bacharoudis, A.E. Filios, M.D. Mentzos and D.P. Margaris, Parametric Study of a Centrifugal Pump Impeller by Varying the Outlet Blade Angle, The Open Mechanical Engineering Journal, no 2, 75-83, 2008. [5] Marco Antonio Rodrigues Cunh and Helcio Francisco Villa Nova, Cavitation modelling of a centrifugal pump impeller, 22nd International Congress of Mechanical Engineering, Ribeirao Petro, Sao Paulo, Brazil, 2013. [6] Mohammed Khudhair Abbas, cavitation in centrifugal pumps, Diyala Journal of Engineering Sciences, pp. 170-180, 2010. [7] Abdulkadir Aman, Sileshi Kore and Edessa Dribssa, Flow simulation and performance prediction of centrifugal pumps using cfd-tool, Journal of EEA, Vol. 28, 2011. [8] Erik Dick, Jan Vierendeels, Sven Serbruyns and John Vande Voorde, Performance prediction of centrifugal pumps with cfd-tools, Task Quarterly 5, no 4, 579 594, 2001. [9] S. C. Chaudhari, C. O. Yadav and A. B. Damo, A comparative study of mix flow pump impeller cfd analysis and experimental data of submersible pump, International Journal of Research in Engineering & Technology, Vol. 1, Issue 3, 57-64, 2013. [10] D. Somashekar and Dr. H. R. Purushothama, Numerical Simulation of Cavitation Inception on Radial Flow Pump, IOSR Journal of Mechanical and Civil Engineering, Vol. 1, Issue 5, pp. 21-26, 2012. [11] Liu Houlin, Wang Yong, Yuan Shouqi, Tan Minggao and Wang Kai, Effects of Blade Number on Characteristics of Centrifugal Pumps, Chinese journal of mechanical engineering, Vol. 23, 2010. [12] Myung Jin Kim, Hyun Bae Jin, and Wui Jun Chung, A Study on Prediction of Cavitation for Centrifugal Pump, World Academy of Science, Engineering and Technology, Vol. 6, 2012.