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The aim of this study is to perform a multi-objective optimization in order to reduce the noise level of a centrifugal fan in early design stages. The main goal is to
minimize the ow-induced noise while providing the required pressure rise at the
operating ow rate. The design procedure begins with a baseline fan. An optimization surface around the baseline design is formed by using the design of experiments method. Accordingly, geometric parameter sets and the corresponding
CAD models are generated. Flow through these fans is simulated via Reynolds
averaged Navier-Stokes equations. Flow data are evaluated to predict the noise
level and the fan performance. Neural network method is employed to determine
the family of optimum points. Two of the Pareto designs are manufactured with
rapid prototyping in order to validate the numerical optimization procedure
via aerodynamic and aeroacoustic experiments. Experiments show that both
designs satisfy optimization goals. 2012 Institute of Noise Control Engineering.
Primary subject classication: 11.4.2; Secondary subject classication: 75.3
INTRODUCTION
Fan noise is one of the major concerns in a large variety of industrial applications. It is essential to integrate
noise emission as a design criterion in the early design
stage in addition to aerodynamic performance and production cost in order to decrease the time and money
spent to design and produce fans.
In fan systems noise is generated aerodynamically,
mechanically and electromagnetically. This paper focuses only on the aerodynamically generated noise in
centrifugal fans, which can be classied as follows1:
1. Interaction between the rotor blades and distortions in the inow or stationary obstacles (like
diffuser blades, tongue etc.) (Fig. 1(a))
2. Relative circulation in blade passages (Fig. 1(b))
3. Boundary layer separation due to increased incidence at high ow rates or due to decreased incidence at low ow rates (Figs. 1(c) and (d))
4. Recirculation at the intake opening and in the
blade row (Fig. 1(e)).
The rst noise source arises periodically at the blade
passing frequency (BPF), which is called a tone. The
a)
b)
Fig. 2An overview of modern CAA methods ( represents any ow variable and rac is the
acoustic pressure).
380
Fig. 3Kinetic energy decomposition in the presence of a predominant frequency, top: with DNS,
middle: with LES, bottom: with unsteady RANS formalismus.
Noise Control Engr. J. 60 (4), July-August 2012
381
Fig. 6Schematic view of the baseline fan, left: side view, right: cross-sectional view.
decrease in rotational direction. In the louder fan, magnitude of the pressure gradients on the volute is higher. To
quantify this phenomenon, the standard deviation of the
pressure on the casing, pstd, is computed.
!
N
1 X
2
pstd
1
pi p
N 1 i1
where N is the total number of nodes, pi is the pressure at
the node i and
p is the surface-averaged pressure value.
Large values of pstd indicate powerful sound sources
and a high OSPL.
In summary, two variables are chosen as indicators of
the OSPL: the average vorticity on a cross-section
across the impeller and the standard deviation of pressure on the volute. Since RANS provides a fair prediction for average ow variables, both of these ow
variables can be predicted accurately with RANS
simulations.
DESIGN OF EXPERIMENTS
r1 (mm)
r2 (mm)
b 1 ( )
b 2 ( )
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
32
32
42
42
37
37
37
37
32
32
42
42
37
37
37
37
32
32
42
42
37
37
37
37
63
67
63
67
65
65
65
65
65
65
65
65
63
63
67
67
65
65
65
65
63
63
67
67
85
85
85
85
80
80
90
90
85
85
85
85
80
90
80
90
80
90
80
90
85
85
85
85
38
38
38
38
33
43
33
43
33
43
33
43
38
38
38
38
38
38
38
38
33
43
33
43
383
averaged values are denoted with an overbar. The closure problem, which arises due to the emergence of
the Reynolds stress tensor, is solved with the Boussinesq approximation by dening the eddy viscosity mt.
@ui @uj
2
0
0
rui uj mt
dij rk
3
@xj @xi
3
The k-e turbulence model calculates the eddy viscosity as a function of the turbulent kinetic energy k and the
turbulent dissipation e.
mt rCm
4.1
@ rkui
@
@xi
@xj
COMPUTATIONAL METHODS
uj
@ r
ui
@p @tij @ rui 0 uj 0
rgj
@xj @xi
@xi
@xi
2
3
Here, ui is the ow velocity in i direction, p is pressure, tij is the shear stress, g is the gravitational acceleration and rui 0 uj 0 is the Reynolds stress tensor. The time
mt @k
m
sk @xj
Gk Gb re Ym Sk
@ui
0
@xi
k2
e
@ reui
@
@xi
@xj
mt @e
m
se @xj
e
e2
C1e Gk C3e Gb C2e r Se
k
k
Where Gk is the generation of turbulence kinetic energy due to the mean velocity gradients (Gk = mt 2jSij Sijj,
where Sij is the strain tensor), Gb is the generation of turbulence kinetic energy due to buoyancy, Ym is the contribution of the uctuating dilatation in compressible
turbulence to the overall dissipation rate. C1e, C2e and
C3e are constants and sk and se are the turbulent Prandtl
4.2
Acoustic Optimization
Optimization is performed to enhance the aeroacoustic properties of the baseline fan, i.e. to decrease its
OSPL. For this purpose two optimization objectives
are formulated:
An important point is that the aerodynamic performance should not be affected adversely by lowering
the OSPL. A fan performance curve represents the
pressure rise developed versus ow rate at a constant
rotational speed. In order to predict the performance
curve numerically, several CFD runs at varying ow
rates have to be performed for each fan. However, the
number of simulations required for a successful optimization process is already so large at to forbid an extensive numerical study. Considering the required
computation time and the data processing effort, ow
is simulated only at the operating point for each fan. It
is assumed that the performance curve is characterized
by the pressure rise developed at that ow rate. In order
to guarantee that the required aerodynamic performance
r1
r2
b1
b2
0.252
0.192
0.224
0.823
0.237
0.757
0.008
0.106
0.044
0.260
0.451
0.312
385
Minimize f11 = x2
Minimize f12 = (x 2)2
NUMERICAL RESULTS
Fig. 13Relative velocity vectors and vorticity distribution of the rst Pareto design.
the reverse ow region obstructs the outlet area, magnitude of the outlet velocity increases locally. This causes
an increase in the OSPL and also a decrease in the aerodynamic performance. In an optimized fan, reverse ow
region should be minimal.
Pressure rise, average vorticity and standard deviation of pressure are extracted from RANS simulations.
The correlations between the ow and the geometric
variables are summarized in Table 2. The blade outlet
radius r2 has a large effect on all ow variables. The
correlation between r2 and P is the largest, which is
a direct result of the Eulers turbomachinery equation:
w U2 c2 U1 c1
Q
cot b2 ;
2pr2 b2
Fig. 14Relative velocity vectors and vorticity distribution of the second Pareto design.
388
surfaces are shown in Figs. 10 through 12. In the projections x- and y-axes are chosen as r2 and b2, since
these geometric parameters have the largest effect on
the investigated ow variables.
The objectives of the optimization procedure are to
minimize both pstd and oave. As the response surfaces
demonstrate, these objectives are competitive. The local
minimum and maximum of pstd and oave surfaces are at
different locations. Furthermore the optimization constraint (i.e. p should be at least 160 Pa) eliminates
a number of points in the optimization space, which
would lead to low pstd and oave values. With these goals
and the constraint, optimization procedure results in
several Pareto designs. Two of the Pareto designs,
which have the longest and the smallest blade chord
lengths, are chosen for further study. These designs
are investigated both numerically and experimentally.
Both Pareto designs are manufactured via rapid prototyping and tested to determine the OSPL values.
Average vorticity distribution and the relative velocity vectors of the Pareto designs are presented in
Figs. 13 and 14. In both Pareto designs no reverse ow
through the blades is visible and large vorticity magnitudes are limited in the near vicinity of the blades.
EXPERIMENTAL VALIDATION
Fig. 16OSPL of the baseline and Pareto designs with respect to pressure rise.
Noise Control Engr. J. 60 (4), July-August 2012
389
2.
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CONCLUSION
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REFERENCES
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