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Research Paper

International Journal of Informative & Futuristic Research ISSN (Online): 2347-1697

Volume 2 Issue 3 November 2014

Abstract

As per the discussion with concern person of the company Foodosavy solutions, Chinchwad, Pune, Maharashtra they are facing many problems regarding centrifugal blower. They are using centrifugal blower for ventilation purpose, also they are using blower to maintain the temperature of food storages (Pulp storage).The present centrifugal blower is made up of from M.S. material here corrosion is a major problem. The ingredients of the same are mixing with fruit pulps, which is harmful, also weight of the present blower is high and vibrations produced by the given centrifugal blower is more, discharge of the present blower is 12000 cfm (cubic feet meter), which is somehow less as per the pulp area of the industry considered. This paper gives the solution to above some problems which are facing the industry i.e. Foodosavy solutions, Chinchwad, Pune. By optimization of critical parts of centrifugal blower by static analysis using FEA. The present centrifugal blower is made up of from M.S. material here corrosion is a major problem; this can be reduced by changing blower material i.e. in this paper SS316L is used to avoid corrosion of the blower. Weight of the centrifugal blower is reduced along with increase in its strength, by optimization of static analysis using FEA for the material MS, SS, and SS316L (Food Grade Steel).

1. Introduction

Blowers are one of the types of turbo machinery which are used to move air continuously with in

slight increase in static pressure. Blowers are widely used in industrial and commercial applications

Optimization Of Critical Parts Of Centrifugal Blower By Static Analysis

Paper ID IJIFR/ V2/ E3/ 019 Page No. 537- 548 Research Area Mechanical Engineering

Key Words Centrifugal Blower, Critical Parts, FEA, Optimization, Static Analysis, SS316L

Kusekar S.K. 1

Scholar M. E., Department of Mechanical Engineering

Brahmdevdada Mane Institute Of Technology(BMIT),

Mangalwedha-Kolhapur, Solapur University (Maharashtra)

Prof. Lavnis A.K. 2

Assistant Professor, Department of Mechanical Engineering

Brahmdevdada Mane Institute Of Technology(BMIT),

Mangalwedha-Kolhapur, Solapur University (Maharashtra)

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ISSN (Online): 2347-1697 International Journal of Informative & Futuristic Research (IJIFR)

Volume 2, Issue 3, November 2014 15th Edition, Page No: 537-548

Kusekar S.K., Prof. Lavnis A.K. : Optimization Of Critical Parts Of Centrifugal Blower By Static Analysis

from shop ventilation to material handling, boiler applications to some of the vehicle cooling systems.

The performance of the fan system may range from free air to several cfm (cubic feet per min.).

Selection of fan system depends on various conditions such as airflow rates, temperature of air,

pressures, airstream properties, etc. Although, the fan is usually selected for nontechnical reasons like

price, delivery, availability of space, packaging etc. The blower is always analyzed by its performance

curves which are defined as the plot of developed pressure and power required over a range of fan

generated air flow. Also these fan characteristic curves can be used to data like fan bhp for selection

of the motor being used.

The centrifugal fans with impellers having blades of Airfoil section are considered as the high

efficiency impellers among the six types Airfoil blades, Backward Inclined single thickness blades,

Backward curved blades, forward curved blades, radial tip blades and radial blades. The present study

gives the design methodology for these high efficiency impellers which include the numerical design

procedure and the CFD analysis of it. The CFD part is used for improvement the results of Static

Pressure generated at the entry to the impeller, static efficiency. The CFD optimization also helped to

improve the flow pattern through the centrifugal fan system. [1]

Centrifugal turbo machines are commonly used in many air-moving devices due to their ability to

achieve relatively high-pressure ratios in a compact configuration compared with axial fans. They are

often found in gas turbine engines, heating ventilation and air conditioning systems, and hydraulic

pumps. Because of their widespread use, the noise generated by these machines often causes serious

environmental issues. The turbo machinery noise is often dominated by tones at blade passage

frequency and its higher harmonics. This is mainly due to strong interactions between the flow

discharged from the impeller and the cutoff of the casing. In addition to discrete tones, the broadband

noise is also generated due to the separation, turbulence mixing, and the vortex interaction process.

[2]

The idea of using splitter vanes in the blade passage of both impeller and diffuser is not

new. Several works mostly experimental have been carried out to assess the suitability of the method.

It is found that a numerical approach using a design analysis tool like CFD is of recent origin and the

whole field flow analysis of the complex flow in a centrifugal fan has been the state of the art in the

domain. Ogawa and Gopalakrishnan, Bhargava and Gopalakrishnan, Fabri performed computations

on splittered centrifugal rotors based upon potential flow models. Mill our examined the same

configuration using a 3-D Euler analysis with simplified viscous forces. They observed that the

primary effect of the splitters was to decrease the loading on the main blades, as well as to reduce the

jet/wake effect at the rotor exit. Fradin performed an extensive set of experiments on the flow fields of

two centrifugal rotors: one with splitters, and one without. In both cases the flow field was transonic.

The geometry of the splitters was the same as the main blades. They were circumferentially

positioned half way between the main blades.

2 Literature Review

Static and Dynamic Analysis of a Centrifugal Blower Using Fea Veeranjaneyulu Itha1,

T.B.S.Rao2, International Journal of Engineering Research & Technology (IJERT) Vol. 1 Issue 8,

October - 2012 ISSN: 2278-0181, pp. 1-11.In this project work this paper is used to study static

and dynamic analysis of blower so as to reduce vibrations & impact.

Numerical Design and Parametric Optimization of Centrifugal Fans with Airfoil Blade Impellers

Atre Pranav C. and Thundil Karuppa Raj R. School of Mechanical and Building Sciences, VIT

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University, Vellore-632014, Tamilnadu, INDIA. In this project work this paper is used to know

how Numerical Design and Parametric Optimization of Centrifugal Fans with Airfoil Blade

impellers help to improve the efficiency of blades & optimize the weight.

A numerical Study on the Acoustic Characteristics of a Centrifugal Impeller with a Splitter Wan-

Ho Jeon1 1 Technical Research Lab., CEDIC Ltd., #1013, Byuksan Digital Valley II, Kasan-

dong.This paper is used to know Acoustic Characteristics of a Centrifugal Impeller with a Splitter

Evaluation of Static & Dynamic Analysis of a Centrifugal Blower Using Fea Mohd Jubair

Nizami, Ramavath Sunman, M.Guru Bramhananda Reddy, International Journal Of Advanced

Trends in Computer Science and Engineering, Vol.2, Issue 7, January-2013, pp. - 316-321. To

study static and dynamic analysis of blower so as to reduce vibrations & impact.

Numerical Analysis of Internal Flow Field of Multi- Blade Centrifugal Fan for Floor Standing

Air- Conditioner Jia Bing Wang Huazhong University of Science and Technology. In this project

work this paper is used to Numerical Analysis of Internal Flow Field of Multi- Blade Centrifugal

Fan for Floor Standing Air- Conditioner so as to improve discharge of the blower.

3. Problem Identification And Problem Definition

Problem Identified

Figure 1: Plant Layout Where Problem Exist

Fruit Pulp Entrance

Fruit Pulp Entrance

Air outlet

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Above figure shows the plant layout of industry where the juice is produced. In this plant centrifugal

blower is used for the ventilation purpose. As per the discussion with concern person of the company

Foodosavy solutions, Chinchwad, Pune, it is found that it is one of the leading company in

Maharashtra and they are producing different types of juice. They are facing many problems

regarding centrifugal blower. They are using centrifugal blower for ventilation purpose, also they are

using blower to maintain the temperature of food storages (Pulp storage).The present centrifugal

blower is made up of from M.S. material here corrosion is a major problem. The ingredients of the

same are mixing with food, which is harmful, also weight of the present blower is high and vibrations

produced by the given centrifugal blower is more, discharge of the present blower is 12000 cfm (cubic

feet meter), which is somehow less as per the pulp area of the industry considered.

4. Scope of Work

As per the discussion with concern person of the company Foodosavy solutions, Chinchwad,

Pune, it is found that currently they are using Flanged Mounted type Centrifugal Blower (HBI-BL-

0768). The specifications of the same are as follows:

Type of blower: Flanged Mounted type Centrifugal Blower (HBI-BL-0768)

Volume flow rate: 12000 cfm (cubic feet meter)

Operating temperature: 16 degree centigrade

Static pressure at operating temperature: 130 mm of Hg

Size of blower/Wheel diameter(AISI316): 735 mm

Fan RPM: 1440

BHP at operating temperature: 13.91 HP

Efficiency: 85%

Motor Power: 12 HP, Torque: 6.91 kg-m

Gas density at operating temperature: 1.21 kg/m3

Static Load: 250 kg, Dynamic Load: 375 kg

Noise Level at Site: 88 db

5 Objectives

1. To reduce corrosion problem of centrifugal blower.

2. To optimize the weight of the centrifugal blower by checking various materials like MS, SS,

SS316L by doing static analysis using FEA.

3. To increase strength of centrifugal blower by doing static analysis using FEA.

6 Methodology

6.1 To Reduce Corrosion Problem Of Centrifugal Blower

The present centrifugal blower is made up of from M.S. material here corrosion is a major problem.

The ingredients of the same are mixing with food, which is harmful. In this paper to avoid corrosion

problem of centrifugal blower SS (316L) material is used instead of MS material due to its corrosion

resistance properties and this material is food grade steel. Stainless steel offers remarkable resistance to

corrosion. There are, however, environments that can cause permanent breakdown of the protective chromium

oxide passive layer on the steel, leading to corrosion on the unprotected surface. Adding alloying elements

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like molybdenum and nitrogen creates high-alloyed or high-performance stainless steels with

improved resistance to corrosion. The Outokumpu Corrosion Handbook addresses the full scale of

corrosion related issues with extensive articles and technical descriptions covering different industrial

sectors. The recently updated handbook contains a wealth of data about the relatively new duplex

family of low-nickel stainless steels and the rich variety of new products and applications. Also

included is special focus on industries with demanding applications such as desalination, pulp and

paper and oil and gas industry. The information should be come in handy for anyone seeking answers

to corrosion issues: designers, engineers, metallurgists and other specialists.

6.1 (a) Why SS instead of MS?

There are lots of stainless steels. Steel, by definition is an alloy containing carbon. The

different alloyed elements give various steels their properties -- including strength, stiffness,

brittleness, corrosion resistance, among others. Mild steel contains 0.16-0.29% carbon. Carbon steel

has carbon content in the range of 0.30-1.70% by weight. Stainless steel has a minimum of 11%

chromium content by mass. Only stainless steel does not corrode."Stainless Steels" don't corrode

because one of their alloying metals (usually chromium or molybdenum) forms a passive migrates to

the surface of the solid and forms a thin, hard oxide layer that is difficult to get through. In addition,

there are electrochemical reasons why chromium and some other elements are resistant to corrosion.

There are several corrosion forms depending on the environment and steel grade in Combination.

Environments causing uniform corrosion on stainless steels are primarily Very strong acids but also

hot (>110°C) alkaline environments. Generally the increase of the amount of alloy elements such as

chromium and molybdenum increases the Resistance to general corrosion.

The general corrosion resistance of different steel grades is basically measured in the

laboratory by immersion in the compound in question and measuring the weight loss after a specified

time of exposure. Environments causing pitting corrosion or crevice corrosion are commonly neutral

Solutions containing high amounts of chlorides. Chromium, molybdenum and nitrogen are the most

essential elements for the resistance to local corrosion of stainless steels. The Pitting Resistance

Equivalent, PRE, is calculated on the basis of the composition of the alloy and gives information on

the relative pitting corrosion resistance of the

Stainless steel grade according to: PRE = %Cr + 3.3%Mo + 16%N

6.2 Static Analysis of Centrifugal Blower To Optimize the Weight and enhance the strength

Software’s to be used

6.2.1 CATIA V5R20

Commonly referred to as 3D Product Lifecycle Management software suite, CATIA supports multiple

stages of product development (CAx), including conceptualization, design (CAD), manufacturing

(CAM), and engineering (CAE). CATIA facilitates collaborative engineering across disciplines,

including surfacing & shape design, mechanical engineering, and equipment and systems engineering.

CATIA provides a suite of surfacing, reverse engineering, and visualization solutions to create,

modify, and validate complex innovative shapes, from subdivision, styling, and Class A surfaces to

mechanical functional surfaces. CATIA enables the creation of 3D parts, from 3D sketches, sheet

metal, composites, molded, forged or tooling parts up to the definition of mechanical assemblies. It

provides tools to complete product definition, including functional tolerances as well as kinematics

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definition. CATIA facilitates the design of electronic, electrical, and distributed systems such as fluid

and HVAC systems, all the way to the production of documentation for manufacturing.

In this paper CAD model is prepared by using above mentioned software with the help of drawing

provided by the company HBL, Pune, which is given bellow:

Figure 2: Drawing of centrifugal Blower

CAD Model:

Figure 3: CAD model

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6.2.2 HYPERMESH 11.0

Altair Engineering is a product design and development, engineering software and cloud computing

Software Company. Altair was founded by James R Scapa, George Christ, and Mark Kistner in 1985.

Over its history, it has had various locations near Detroit, Michigan, USA. It is currently

headquartered in Troy, Michigan with regional offices throughout America, Europe and Asia.

Altair Engineering is the creator of the Hyper Works suite of CAE software products. Altair

Hyper Mesh is a high-performance finite element pre-processor to prepare even the largest models,

starting from import of CAD geometry to exporting an analysis run for various disciplines.

Hyper Mesh enables engineers to receive high quality meshes with maximum accuracy in the shortest

time possible. A complete set of geometry editing tools helps to efficiently prepare CAD models for

the meshing process. Meshing algorithms for shell and solid elements provide full level of control, or

can be used in automatic mode.

FEA Model of Centrifugal Blower Fan:

Figure 4: FEA model of centrifugal blower fan with meshing

6.2.3 ANSYS 14.5

ANSYS Work bench can be thought of as a software platform or framework where you perform your

analysis (Finite Element Analysis) activities. In other words, workbench allows you to organize all

your related analysis files and databases under same frame work. Among other things, this means that

you can use the same material property set for all your analyses.

The ANSYS Workbench platform allows users to create new, faster processes and to efficiently

interact with other tools like CAD systems. In this platform working on Metaphysics simulation is

easy. Those performing a structural simulation use a graphical interface (called the ANSYS

Workbench Mechanical application) that employs a tree-like navigation structure to define all parts of

their simulation: geometry, connections, mesh, loads, boundary conditions and results. By using

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ANSYS workbench the user can save time in many of the tasks performed during simulation. The

bidirectional links with all major CAD systems offer a very efficient way to update CAD geometries

along with the design parameters.

Static Analysis for Equivalent stress:

Static analysis of critical part of centrifugal blower i.e. fan is done by using FEA. Fan is core

part of centrifugal blower and all the performance of blower is totally depends upon fan, so fan is

chosen critical part of centrifugal blower for the analysis. Analysis is done for the material MS, SS,

and SS316L respectively, in order to check Equivalent stresses induced in each material.

Figure 5: Equivalent Stress of MS blower Fan, MPa

Figure 6: Equivalent Stress of SS blower Fan, MPa

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Figure 7: Equivalent Stress of SS316L blower Fan, MPa

Static Analysis for Total Deformation:

Figure 8: Total Deformation of MS blower Fan, mm

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Figure 9: Total Deformation of SS blower Fan, mm

Figure 10: Total Deformation of SS316L blower Fan, mm

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Figure 11: Total Deformation of SS316L blower Fan, by reducing thickness1mm

7 Results & Discussions

Table 1: The maximum deflection induced in metallic blower fan

Sr. No. Material Stress (MPa) Deformation (mm) Weight (Kg)

1 MS 7.0473 0.0421 35.93

2 SS 7.047 0.0404 35.93

3 SS316L 7.067 0.0365 36.394

4 SS316L (Optimized) 6.68 0.041287 33.073

The maximum deflection induced in metallic blower fan i.e. SS316L material is 0.03655 mm, which

is in safe limits. Hence based on rigidity the design is safe. The maximum induced stress for the same

material is 7.06 Mpa which is less than the allowable stress (120 Mpa).Hence the design is safe based

on strength. If we compare corresponding deformation of the material MS, SS on above results

SS316L material having minimum deformation therefore there are less chances of failure of the

blower fan as compare to other two materials. Hence the strength of blower gets increased because of

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the SS316L material. From the above result table it is clear that weight of the SS316L blower fan

material is minimum as compared to other material, hence weight of the blower fan optimized.

8 Conclusions

Corrosion problem of the centrifugal blower can be reduced by using material SS316L, which

is highly corrosion resistant. Hence there will not be any mixing of ingredients of corrosion in

fruit pulps as discussed in problem definition.

Weight of the Centrifugal blower is optimized by using SS316L material (i.e.33.073Kg which

is less as compared to other materials).

SS316L material having minimum deformation therefore, there are less chances of failure of

the blower fan as compare to other two materials. Hence the strength of blower increases

because of the SS316L material.

From above result we conclude that SS316L steel is the best material for blower

manufacturing as per industrial requirement.

9 Future Scope

The present work gives only static analysis of critical part of centrifugal blower in order to optimize

the weight & enhance strength of the blower also this paper provides solution to the corrosion

problem by suggesting alternative material. However this paper does not gives the modal analysis of

centrifugal blower as the fan is rotating member so it produces vibrations, in future there is always

scope of modal analysis and CFD analysis of the blower fan, in order to increase performance of the

given centrifugal blower.

10 References [1] Staticand Dynamic Analysis of a Centrifugal Blower Using FeaVeeranjaneyulu Itha, T.B.S.Rao,

International Journal of Engineering Research &Technology (IJERT) Vol.1.Issue 8,

. October –2012 ISSN: 2278-0181, pp. 1-11

[2] Numerical Design and Parametric Optimization of Centrifugal Fans with Airfoil Blade Impellers Atre

Pranav C. and Thundil Karuppa Raj R. School of Mechanical and BuildingSciences, VIT University,

Vellore-632014, Tamilnadu, INDIA.

[3] A numerical Study on the Acoustic Characteristics of a Centrifugal Impeller with a Splitter Wan-Ho

Jeon1 1 Technical Research Lab., CEDIC Ltd., #1013, Byuksan Digital Valley II.

[4] Evaluation of Static & Dynamic Analysis of a Centrifugal Blower Using FeaMohd Jubair Nizami,

Ramavath Suman, M.Guru Bramhananda Reddy,International Journal Of Advanced Trends in

Computer Science and Engineering, Vol.2, Issue 7, January-2013,

pp. -316-321.

[5] Numerical Analysis of Internal Flow Field of Multi- Blade Centrifugal Fan for Floor Standing Air-

Conditioner Jia Bing Wang Huazhong University of Science and Technology.

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