CFD Optimization Analysis of a Cooling Fan for Mining Dump Truck

Abstract

Axial flow fans are widely used in our daily lives such as automotive cooling systems, electronic appliances and air conditioning. The factors that affect the aerodynamic performance of axial flow fans include blade number, fan diameter, hub ratio, blade angle, rotating speed, etc. This paper investigates effects of hub ratio and bladenumber on the aerodynamic performance of the axial flow fan of the radiator of a dump truck we previously designed for mining. With the computational fluid dynamics (CFD) method, the fans operation condition, such as entry static pressure, effective power and flow rate, are numerically simulated with various hub ratios and blade numbers. The results of the numerical simulations are quantitatively analyzed and curves of fans performance changing with hub ratio and blade number are given. An optimization design for the cooling fan is conducted. The results of numerical simulation give conclusion that an increase of 5.6% of the vacuum static pressure and an increase of 3% of flow rate can be obtained when the hub ratio is between 500-600mm, with the same or even less power consumption. The flow rate increment reaches its peak at 8%, while power consumption efficiency is almost linearly increased, when the blade number increases to be in the range of 8 to 10. That is to say when the blade number is between 8 to 10, the fan is apparently making better use of energy. Compared with experimental method, computational fluid dynamics (CFD) method can reduce design circle and lower cost. The CFD results provide guidance to improvement of design efficiency and energy utilization.