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CFD Simulations of an Automotive HVAC Blower: Operating
under Stable and Unstable Flow Conditions
Moulay BelHassan and Asad Sardar
Air International Thermal Systems
Reza Ghias
ANSYS Inc.
Copyright © 2007 SAE International
• A new eddyviscosity formula involving a variable C The realizable Kε model has been extensively validated
originally proposed by Reynolds [8]. for a wide range of flows [912], including rotating
• A new model equation for dissipation (ε) based on homogeneous shear flows, free flows including jets and
the dynamic equation of the meansquare vorticity mixing layers, channel and boundary layer flows, and
fluctuation separated flows. For all these cases, the performance of
the model has been found to be substantially better than
that of the standard Kε model. It is worth to note that
The term "realizable'' means that the model satisfies the realizable Kε model resolves the roundjet anomaly
certain mathematical constraints on the Reynolds i.e. it predicts the spreading rate for axisymmetric jets as
stresses, consistent with the physics of turbulent flows. well as that for planar jets.
Neither the standard Kε model nor the RNG Kε model
is realizable [2]. MULTIPLE ZONES APPROACH
An immediate benefit of the realizable Kε model is Numerical simulations of multiple moving parts or
relatively accurate prediction of the spreading rates in stationary surfaces which are not surfaces of revolution
both planar and round jets. It is also likely to provide have encounter challenges. For these problems, one
superior performance for flows involving rotation, must break up the model into multiple fluid/solid cell
boundary layers under strong adverse pressure zones, with interface boundaries which separate the
gradients, separation, and recirculation. zones. Zones with moving components can then be
solved using the moving reference frame equations,
Both the realizable and RNG Kε models have whereas stationary zones can be solved with the
shown substantial improvements over the standard stationary frame equations. The manner in which the
Kε model where the flow features include strong equations are treated at the interface lead to two
streamline curvature, vortices, and rotation. Since approaches which are supported in FLUENT [2]:
the model is still relatively new, it is not clear in
exactly which instances the realizable Kε model • Multiple Rotating Reference Frames (MRF).
consistently outperforms the RNG model. However, • Sliding Mesh Model (SMM).
initial studies have shown that the realizable model
provides the best performance of all the Kε model MRF is a steadystate approximation in which individual
versions for several validations of separated flows cell zones move at different rotational and/or
and flows with complex secondary flow features translational speeds. The flow in each moving cell zone
[9,12]. is solved using the moving reference frame equations. If
the zone is stationary, the stationary equations are used.
At the interfaces between cell zones, a local reference
One limitation of the realizable Kε model is production frame transformation is performed to enable flow
of the nonphysical turbulent viscosities in situations variables in one zone to be used to calculate fluxes at
when the computational domain contains both rotating the boundary of the adjacent zone. MRF is relatively
and stationary fluid zones (e.g. multiple reference simple and more efficient than SMM approach. It should
frames, rotating sliding meshes). This is due to the fact be noted that the MRF approach does not account for
that the realizable Kε model includes the effects of the relative motion of a moving zone with respect to
mean rotation in the definition of the turbulent viscosity. adjacent zones (which may be moving or stationary); the
grid remains fixed for the computation. This is analogous
to freezing the motion of the moving part in a specific MESH GENERATION
position and observing the instantaneous flowfield with
the rotor in that position. Hence, the MRF is often The surface mesh was generated in Unigraphics
referred to as the "frozen rotor approach." (UG).The surface mesh quality was improved using in
ICEMCFD and volume mesh was created in Tgrid.
While the MRF approach is clearly an approximation, it Arbitrary interface was created between moving and
can provide a reasonable model of the flow for many stationary grids. The mesh consisted of a total of
applications. For example, the MRF model can be used 3,800,000 tetrahedral cells including 2,650,000 cells in
for turbomachinery applications in which rotorstator rotating zone. Figure 1 shows the created mesh that was
interaction is relatively weak, and the flow is relatively used for this study.
uncomplicated at the interface between the moving and
stationary zones. In mixing tanks, for example, since the BOUNDARY CONDITIONS
impellerbaffle interactions are relatively weak, large
The Steady state calculation using the Kε realizable
scale transient effects are not present and the MRF
and multiple rotating reference frame model were used
model can be used.
for high airflow regimes (3023, 3290, 3612 rpm). For
Another potential use of the MRF model is to compute a higher blower speeds and low airflow (3923 rpm, 50
flow field that can be used as an initial condition for a cfm), the MRF model failed to deliver good results due
transient sliding mesh calculation. This eliminates the to high turbulence and airflow instabilities. The sliding
need for a startup calculation. The multiple reference Mesh model was employed to simulate this kink of flow.
frame model should not be used, however, if it is A zero pressure inlet was used at the inlet boundary.
necessary to actually simulate the transients that may The outlet pressure was derived from the experimental
occur in strong rotorstator interactions, the sliding mesh data. A logarithmic law of the wall relative to frame is
model alone should be used. used in moving rotor surfaces.
The sliding mesh model approach is, on the other hand,
inherently unsteady due to the motion of the mesh with
time. In this approach, motion of stationary and rotating
components in a rotating machine will give rise to
unsteady interactions. These interactions are generally
classified as follows:
Table 2: The geometric characteristics of the blower.
Wheel
Fan inlet diameter 127 mm
Fan outlet diameter 160 mm
Fan width 80 mm
Number of blades 43
Inlet blade angle 23 deg
Outlet blade angle 60 deg
Blade chord length 17.6 mm
Pitch to chord ratio 66 %
Scroll
Casing width 85 mm
Cutoff edge distance 13 mm
Expansion angle at θs=210deg 5.8 deg
Diameter of inlet opening 137.5 mm
In order to determine the fan performance, the blower
and scroll are attached to an FM600 airflow test bench
which is dual chamber AMCA certified design (see
Figures 2 and 3). The test set up and measurements of
blower aerodynamic performance were made according
to ANSI/AMCA Standard 21085 [6].
Figure 1: Shows the mesh in different parts of the blower. The blower inlet configuration was a “free type”; that is
open to atmosphere. The fan total pressure was
measured at the FM600 airflow chamber (averaged over
It is worth to mention that the outlet boundary was 4 piezometric static pressure tabs). The volumetric
extended in order to reduce the effect of the numerical airflow was measured in the dual chamber using ASME
reflections from outlet on the flow field. All steady state certified flow nozzles. The test blower was powered
simulations were begun using a first order upwind using the DC Power supply. The rotational speed of the
scheme for pressure, momentum, turbulent equations blower wheel was measured using a fiberoptic sensor
and after converging, they were switched to the second connected to a digital display on the FM600 airflow
order upwind. bench. Signal pick was based on reflective tape
attached to the rotating wheel.
This time step in unsteady calculations was related to
the rotational speed of the impeller and was small The blower performance curves were obtained using
enough to get the necessary time resolution and to fixed voltages (i.e., motor voltages selected were: 12V,
capture the phenomena due to the blades passage and 13V & 14V). Using the auxiliary FM600 airflow bench fan
their interactions with the volute casing wall [13]. and dampervalve combination, the airflow was set for
each data point (ranging from 50 cfm to 350 cfm), while
the fan static/total pressure and blower rpm were speeds and outlet pressure. Last row shows the results
measured at each data point. Then current draw at each for unsteady transient simulation.
data point was obtained through a shunt. This was
repeated for each data point until full airflow range was The same tetrahedral mesh has been used for all cases.
tested (from 50 to 350 cfm). The range of airflow testing Also The MRF approach was employed for the first four
at the various voltages tested allowed enough spread in configurations, while SMM approach was used for
blower rpm for matching different rpm and pressure configuration 5. Ve Blower Performance Curves: free Inlet, no LPM
06-AIUS-TR-00558
conditions used in CFD analysis. The blower 1400
performance curves based on pressure versus airflow,
12 volts
current versus blower speed, and current versus airflow
1200 13 volts
are shown in Figures 4, 5, and 6 respectively.
14 volts
1000
Pressure (Pa)
800
600
400
200
0
0 50 100 150 200 250 300 350 400
Airflow ( CFM)
Figure 4: Blower Performance: Pressure vs. airflow.
Ve Blower Performance Curves: free Inlet, no LPM
06-AIUS-TR-00558
30
12 volts
13 volts
25
14 volts
20
Current (Amps)
Figure 2: The blower and scroll attached to an FM600 airflow 15
test bench.
10
12.5 in 29.5 in
Airflow Nozzles 5
location
Blower attaches here
0
2500 2700 2900 3100 3300 3500 3700 3900 4100 4300
Blower Speed ( RPM)
Figure 5: Blower Performance: Current vs. blower speed
Ve Blower Performance Curves: free Inlet, no LPM
06-AIUS-TR-00558
30
12 volts
20
4 Static Pressure
Current (Amps)
Taps (piezometric)
15
Figure 3: Shows the locations for measurement of flow
variables. 10
RESULTS AND ANALYSIS
5
0
Table 3 shows a comparison of the volume rates 0 50 100 150 200 250 300 350 400
difference of the total air flow from test and CFD is within
150
100
5%. 50
0
400 600 800 1000 1200
CFD result shows an overestimate in total airflow Pressure (Pa)
• tke spreads over a large region circumferentially and
axially in low flow rate configuration, whereas it is
highly concentrated in the lower portion of the blade
exit region and close to the scroll cutoff region in
high flow rate configuration.
Section 1: Circumferential Section
Section 2: Mid section
a
Figure 9: Shows (a) Pressure, (b) Velocity vector, (c) Total
pressure, (d) Turbulent kinetic energy, and (e) Turbulent
intensity distributions at section 2 in configuration 1.
c
a
d d
e
e
a
Figure 10: Shows (a) Pressure, (b) Velocity vector, (c) Total
c
pressure, (d) Turbulent kinetic energy, and (e) Turbulent
intensity distributions at section 1 in configuration 1.
d
c
e
Figure 11: Shows (a) Pressure, (b) Velocity vector, (c) Total
pressure, (d) Turbulent kinetic energy, and (e) Turbulent
intensity distributions at section 2 in configuration 5.
Figure 12: Shows (a) Pressure, (b) Velocity vector, (c) Total
pressure, (d) Turbulent kinetic energy, and (e) Turbulent
intensity distributions at section 1 in configuration 5.
3. Eck B., " Fans: Design and Operation of Centrifugal,
AxialFlow and CrossFlow Fans", Translated and
edited by Azad R.S. and Scott D.R.), Pergamon
CONCLUTIONS Press, 1973.
4. D. Fischer, "Airflow Simulation Through Automotive
CFD analysis and blower performance measurements Blowers Using Computational Fluid Dynamics ",
were conducted on a forward curved centrifugal blower SAE 950438
5. E. Kwon, K. Baek, N. Cho, "Some Aerodynamic
(for automotive HVAC applications).
Aspects of Centrifugal Fan Characteristics of an
Automotive HVAC Blower ", SAE 2001010291
Comparison of predicted total airflow rates, using a 6. AMCA 21085, “Laboratory Methods of Testing Fans
steady state Kε realizable model, showed a good for Fating”
correlation with three test configurations. For the fourth 7. T.H. Shih, W. W. Liou, A. Shabbir, Z. Yang, and
J. Zhu., "A New Kε EddyViscosity Model for High
configuration (high pressure, low airflow), the predicted
Reynolds Number Turbulent Flows Model
total airflow was highly overestimated. Development and Validation", Computers Fluids,
24(3):227238, 1995.
For the fourth configuration, the CFD results analysis 8. W. C. Reynolds, "Fundamentals of turbulence for
indicate that an increase in flow blockage across the turbulence modeling and simulation", Lecture Notes
blades leads to higher recirculation and flow reversal, for Von Karman Institute Agard Report No. 755,
1987.
which contributes to higher turbulence levels and flow 9. T.H. Shih, W. W. Liou, A. Shabbir, Z. Yang, and
unsteadiness. As a result, using a transient approach for J. Zhu, "A New Kε EddyViscosity Model for High
this configuration was necessary. Reynolds Number Turbulent Flows Model
Development and Validation", Computers Fluids,
By switching to a transient simulation, the predicted total 24(3):227238, 1995.
10. B. E. Launder and D. B. Spalding. “Lectures in
airflow was in reasonable agreement with measured Mathematical Models of Turbulence” , Academic
total airflow. The general flow structure appeared to be Press, London, England, 1972.
similar for all configurations, although with differences 11. V. Yakhot and S. A. Orszag. “Renormalization Group
with respect to the location and intensity of the vortices. Analysis of Turbulence: I. Basic Theory” Journal of
Scientific Computing, 1(1):151, 1986
12. S.E. Kim, D. Choudhury, and B. Patel.
This CFD study shows that numerical results for a
“Computations of Complex Turbulent Flows Using
forward curved blower are in good agreement with test the Commercial Code FLUENT” In Proceedings of
results and can be used for accurate prediction of the the ICASE/LaRC/AFOSR Symposium on Modeling
airflow characteristics of automotive HVAC systems. Complex Turbulent Flows, Hampton, Virginia, 1997.
13. M. Younsi, F. Bakir, S. Kouidri, R. Rey, “Influence of
Impeller Geometry on the Unsteady Flow in a
In order to have an accurate analysis of the
Centrifugal Fan: Numerical and Experimental
unsteadiness in low flow rate configurations, it is Analysis”, Internal paper of Ecole Superieure d’Arts
recommended to perform the transient simulations of et Metiers – France.
the whole blower including wheel, inlet and scroll and 14. R.J. Kind, M.G. Tobin, “Flow in a centrifugal fan of
the squirrelcage type”, Transactions of the ASME,
compare the results to corresponding pressure, velocity,
84/Vol. 112, January 1990.
and turbulence results measured in experimental test. 15. Raj, D.and Swim, W. B., 1981,”Measurements of the
Specially, the effect of the backflow through the blade mean flow velocity and velocity fluctuations at the
passages close the cutoff scroll should be evaluated by exit of an FC centrifugal fan rotor”, ASME Journal of
Engineering for Power, Vol. 103, pp. 393399.
experiments. In addition, the position of the stagnation
point of the cutoff scroll area and the degree of the flow
blockage both in the inlet and outlet of the blower should
be confirmed by test results.
REFERENCES