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\title{Experimental and Simulation Performance for Fan Extraction System}
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\begin{document}

             \author[1]{Professor Klaudio  Bari}

             \affil[1]{  University of Derby}

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\date{\small \em Received: 6 December 2016 Accepted: 3 January 2017 Published: 15 January 2017}

\maketitle


\begin{abstract}
        


Computational Fluid Dynamics (CFD) is commonly implemented in industry to perform fluid-flow and heat-transfer analysis, however, rarely used in computational material engineering. The project aim is to select a biodegradable composite for impeller used in conventional domestic extraction fan. The  analysis starts with a validation of the experimental values of thrust obtained from different materials used to manufacture impellers tested in a wind tunnel. An identical model was used in the CFD simulation using STAR-CCM + software. The study compares thrust values of different impellers made from thermoplastic polymer such as Acrylonitrile Butadiene Styrene (ABS), Polylactic Acid (PLA) and composite materials such as Bronze-fill, fibre glass and wood fill composites. The results revealed that composite impellers like Bronze-fill and Glass fibre fill composites perform better in term of thrust than traditional ABS impeller. Also, biodegradable wood fill composite shows competitive alternative to replace the conventional ABS impeller used in fan extraction units. A cost comparison shows that wood-fill composite impeller would be cheaper to manufacture using Polymer Injection Moulding (PIM). A crack growth can be monitor using Acoustic Emission (AE) during solidification of molten plastic.

\end{abstract}


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\let\tabcellsep& 	 	 		 
\section[{Introduction}]{Introduction}\par
raditionally, Computational Fluid Dynamics (CFD) is commonly used in industry to perform fluid-flow and heat-transfer analysis of turbo machinery equipment. The use of CFD plays an important role in fluid mechanics. Due to the progress of numerical methods and computer capability, the impeller design nowadays has been analysed by using numerical analysis and CFD software to predicttimpeller performance \hyperref[b0]{(Shah 2013}). However, both manufacture and design cannot be done easily with out sufficient details about experimental outcomes. If there is discrepancy between result obtained from the CFD and experimental set up, the impeller cannot be manufactured in a real production line \hyperref[b1]{(Kaminsky, 2012)}.\par
The project used STAR-CCM+ as a simulation software tool of an identical model of domestic fan extraction placed in a wind tunnel, which was manufactured in the University of Derby workshop. Validation of the results in such case is necessary because the designs and implementers of publically used components could make errors in operation of the component. These errors will result in term of undetected faults in the impeller blades, numerous errors such as loss of system integrity, electric fire hazard in the motor, and worst of all loss of human lives. The mission of validating and verifying is therefore to find out and correct these errors that causes misinterpretation, as early as possible thus preventing exposure of the faulty components or systems to customers. In order to validate the experimental results, an identical design of3D parts was assembled to duplicate a real physical model of fan extraction system and test it in the wind tunnel. The challenge in this project that the simulation software does not possess a tool to select appropriate material of the impeller during simulation, thus a comparison between the simulation/experimental results will be limited to one scenario. Wood-fill/PLA composite impeller was proposed as an option for domestic fan extraction system. 
\section[{a) Aim}]{a) Aim}\par
The goal of this study is to analyse the thrust of different types impellers in a wind tunnel and examine the performance and in particular wood-fill composite impeller. The reuse and recyclability of impellers were considered in the selection of the best bio degradable material, thus have gaining a positive environment impact due to recycling and reuse. 
\section[{b) Star CCM+ Simulation}]{b) Star CCM+ Simulation}\par
The use of STAR-CCM+ is becoming more and more important, as it is one of the most powerful CFD software. Ideally when choosing a CFD software, a compromise had to be made between accessibility and powerful functionality. However, STAR-CCM+ integrates a set of tools that perform design, mesh and analyse simulations without having to compromise the accuracy of the boundary conditions. It was chosen in this study because of its ability to solve complex boundary conditions involving several laws of physics with minimum user effort. The software usage in this study is based solely on its rapid expansion through the ranks of CFD and other mechanical engineering fields. \hyperref[b2]{(Kaewnai, 2009)} has an objective of using the CFD technique in analysing and predicting the performance of a radial flow-type impeller of centrifugal pump. Although currently there is limited information available of the physics models used axial flow type This information can be used at some point in term of comparison criteria and source of error which may encountered during both experimental and simulation process. In the present study, the main concern is the noise and vibration impact on the multi pressure sensors deployed in our wind tunnel. Most research on impellers using STAR-CCM+ was performed ontide, wave and wind energy generation turbines using open air media (Kumawat, H. (2014).However, the validation of low speed air stream (< 10 m/s) a wind tunnel has never been investigated due to lack of interest. 
\section[{II.}]{II.} 
\section[{Methodology}]{Methodology}\par
This research investigates the thrust of an axial impeller rotated at low rotation speed (RPM=10,000).\par
Most of other sresearches were performed mainly on predicting flow pattern of air in axial impellers at above 350 m/s (Kumawat, 2014) Impeller: The impeller parts have been manufactured using an Ultimaker2 3D printer via a process of fused filament fabrication (FFF), also known as fuse deposition modelling (FDM) as shown in Figure \hyperref[fig_0]{1}. This process deposits a polymer filament into a heated extrusion nozzle. The nozzle moves to a build plate and constructs the 2D cross section of the 3D model; the cross section moves down and allows the nozzle to print another 2D cross-section of the model on the initial 2D cross-section, using heat as an adhesive. The layers are stapled till the 3D model is completed. Before printing the CAD model of the impellers, it had to be prepared using software called CURA; it is associated with Ultmaker2 (the 3D printer model). The Ultmaker2 does not support files from other software, hence a change of file extension to STL was done in order to open the file in CURA. CURA was used in changing the printing conditions such as; size and shape of components, and Layer height (the movement of the control plate between each layer). Note that the higher the layer height the lower the printing quality, just as pixels in 2D picture printing. There are two other parameters that determine the finishing of the  After successfully printing the impeller in ABS and PLA, three other composites were used. Wood-fill (70\% PLA, 30\% recycled Wood-fibre), Bronze-fill (a composite of PLA and fine bronze particles) and Glass fibre (70\% PLA, 30\% E-Glass fibre). The same layer height and infill parameters were used for Bronze-fill (0.1mm layer height, 25\% infill), however Wood-fill required a layer height of 0.25mm due to its lower printing temperature. All five impellers and the backward stator are shown in Figure \hyperref[fig_3]{3}. The material properties of the impellers are listed in Table \hyperref[tab_0]{1}.   
\section[{a) Wind Tunnel}]{a) Wind Tunnel}\par
The wind tunnel was manufactured in our workshop using laser cut machine and assembled using expert technicians to fit all components inside. It is a cylindrical geometry tunnel of synthetic smooth PVC plastic in order to reduce intrinsic drag from air streams and supported by ply wood frames to reduce vibration. It was mainly designed to minimise the turbulence created by the rotating impeller. The outlet air streams measured by 0.5 mm 2 highly sensitive pressure sensor that measures the velocity and mass flow rate. The impeller, fan case and the other components used in the experiment shown in Figure  {\ref 4}.  This is a non-rotating fan stationed in the tunnel to laminate the level of turbulence in exited at the outlet. This stator acts like a frame fastened to the walls of the container, to make sure all air streams are aligned to horizontal axis in order to prevent turbulence at the outlet end. Figure \hyperref[fig_7]{6} shows the horizontal view of outlet end of the wind tunnel.   
\section[{Results}]{Results} 
\section[{a) Experimentation Case}]{a) Experimentation Case}\par
A mass rate and velocity meter is fixed on the outlet of the tunnel to measure the outlet mass rate and air velocity. By replacing the impeller for each batch process, the thrust can be measured for different impellers using the equation1.??????????? = ???????????????? ?? ???????? ð??"ð??"????ð??"ð??" ???????? (1)\par
The velocity meter is connected to PC. The probe has very high sensitivity and an accuracy of ± 0.3\%. With that kind of sensitivity and accuracy, the application of the device on the tunnel would require a level of precision; any sudden vibrations could affect the accuracy of the readings and cause a variation in results as shown in Figure  {\ref 7}. The averaged outlet velocity, mass flow and thrust measured using the manometer are listed in Table \hyperref[tab_1]{2}.  
\section[{b) Simulation Case}]{b) Simulation Case}\par
The first step is use of a CAD based software (Solid Works) to draw the structure and topology of complete wind tunnel includes the internal parts. As the impellers were already designed in a CAD based software, a simple transfer of the drawing would merely suffice to Solid Works. The second step is to import the identical model geometry from solid work file (STL format) to star CCM+. The wind tunnel, fan case, motor, cables and impeller were identically represented and were applied to the same boundary conditions used in the experiment case. After that, appropriate physics models (RANS with K-epsilon correction) were applied to specify the behaviour of the turbulence produced as shown in Figure  {\ref 8}. 
\section[{Figure 8: c) Simulation Results}]{Figure 8: c) Simulation Results}\par
The model meshed using different size of Polyhedral size for the fluid region (1-10 mm) and fixed Prism layer size of 1 mm for surface structure region.\par
The velocity value-location from the outlet wind tunnel pipe of from different mesh size are shown in It was found that mesh size between 1-3 mm was appropriate and it would produce repeatable results. The similar outlet velocity profile is evident when comparing the outlet velocity profile in Figure \hyperref[fig_0]{10} and Figure \hyperref[fig_0]{11}.\par
The quality of the model mesh was over 99.9\%. This was achieved using automated mesh which uses surface and geometry mesh control.\par
The model configuration shows the exact real case, motor, guide vain, wires, fan and wind tunnel case.  IV. 
\section[{Global}]{Global} 
\section[{Experimental Results}]{Experimental Results}\par
Similarly, the outlet mass rate and velocity of different impellers, from the wind tunnel were measured using the bespoke manometer. The averaged of 10 readings were obtained and the final results are summarized in Figure \hyperref[fig_11]{12}.  
\section[{Discussion}]{Discussion}\par
The discussion of the results can be summarised as below:\par
? Composite impellers like Bronze-fill/PLA and glass Fibre fill/PLA composites showed better performance in term of thrust compared to traditional ABS impeller used in domestic extraction fan system.\par
? Wood fill/PLA composite as a biodegradable material to shows similar thrust values to simulation results. This makes it attractive to be used in as base line in simulation using Star CCM+. ? A modification was proposed to CD-Adapco to addon a Rigidity Factor (RF) in the rotation section in the software. This will enable the user to choose an appropriate material factor in the simulation using rotation reference frame. Plastic Impellers are manufactured using one of our Pre-Tooled Plastic Impeller molds. This method saves molds development time and money by using our existing tooling inventory. Also, the time from placement of order to delivery of actual parts is significantly reduced. The cost unit of wood fill/PLA composite impellers will be reduced to half using the advance air plastic injection molding.\par
Advanced Air produces plastic injection molded impellers for a wide variety of OEM, commercial and industrial applications. The early results show that the design and manufacture high quality impellers have meet our exact specifications. The use innovative manufacturing facilities to produce plastic impellers and impeller products that give us 100\% recyclability and zero impact on the environment, maximum durability and high performance.\par
In order to detect and monitor crack growth during solidification of the impeller, Acoustic Emission (AE) could be a micro-scale detection tool to monitor crack and porosity of the final product. AE technique also uses relatively simple but effective means of monitoring the time progress development of different failure mechanisms during air injection molding. The data of the emission can be analysed and differentiated to provide instantly alarm for shrinkage rate during solidification of the impeller in the mold  {\ref (Spasova, 2008)}.\par
VI. 
\section[{Conclusion}]{Conclusion}\par
Biodegradable impellers are promising material to replace the current ABS used in domestic fan extraction system. This will have a significant positive environmental impact by recycling the used impellers. An early result shows that wood-fill/PLA impeller was viable to be manufactured using traditional extrusion process to reduce cost of production. Plastic Mold Injection (PIM) was selected as a cost effective manufacture process in the mass production of woodfill/ PLA composite impeller.\begin{figure}[htbp]
\noindent\textbf{1}\includegraphics[]{image-2.png}
\caption{\label{fig_0}Figure 1 :}\end{figure}
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\noindent\textbf{}\includegraphics[]{image-3.png}
\caption{\label{fig_1}}\end{figure}
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\noindent\textbf{2}\includegraphics[]{image-4.png}
\caption{\label{fig_2}Figure 2 :}\end{figure}
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\noindent\textbf{3}\includegraphics[]{image-5.png}
\caption{\label{fig_3}Figure 3 :}\end{figure}
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\noindent\textbf{}\includegraphics[]{image-6.png}
\caption{\label{fig_4}}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{}\includegraphics[]{image-7.png}
\caption{\label{fig_5}}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{}\includegraphics[]{image-8.png}
\caption{\label{fig_6}}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{6}\includegraphics[]{image-9.png}
\caption{\label{fig_7}Figure 6 :}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{}\includegraphics[]{image-10.png}
\caption{\label{fig_8}}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{}\includegraphics[]{image-11.png}
\caption{\label{fig_9}D}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{9201711}\includegraphics[]{image-12.png}
\caption{\label{fig_10}Figure 9 : 2017 DFigure 11 :}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{12}\includegraphics[]{image-13.png}
\caption{\label{fig_11}Figure 12 :}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{}\includegraphics[]{image-14.png}
\caption{\label{figure14}}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{}\includegraphics[]{image-15.png}
\caption{\label{figure15}}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{1} \par 
\begin{longtable}{P{0.19304029304029302\textwidth}P{0.10274725274725274\textwidth}P{0.136996336996337\textwidth}P{0.09963369963369963\textwidth}P{0.11208791208791209\textwidth}P{0.08406593406593406\textwidth}P{0.12142857142857141\textwidth}}
Material\tabcellsep Fan Size\tabcellsep Tolerance\tabcellsep Density g/cm 3\tabcellsep Melting Point( o C)\tabcellsep Tg( o C)\tabcellsep Impact Strength KJ/m 2\\
ABS\tabcellsep 90 mm\tabcellsep ±0.10mm\tabcellsep 1.03\tabcellsep -\tabcellsep 105\tabcellsep 36\\
PLA\tabcellsep 90 mm\tabcellsep ±0.10mm\tabcellsep 1.24\tabcellsep 150-160\tabcellsep 60-65\tabcellsep 7.5\\
Wood-fill/PLA\tabcellsep 90 mm\tabcellsep ±0.05mm\tabcellsep 1.29\tabcellsep 220\tabcellsep 60-65\tabcellsep 17.4\\
Glass fibre fill/PLA\tabcellsep 90 mm\tabcellsep ±0.05mm\tabcellsep 3.1\tabcellsep n/a\tabcellsep n/a\tabcellsep 21.1\\
Bronze-fill/PLA\tabcellsep 90 mm\tabcellsep ±0.05mm\tabcellsep 3.9\tabcellsep n/a\tabcellsep n/a\tabcellsep 22.5\end{longtable} \par
 
\caption{\label{tab_0}Table 1 :}\end{figure}
 \begin{figure}[htbp]
\noindent\textbf{2} \par 
\begin{longtable}{P{0.28031914893617016\textwidth}P{0.19893617021276597\textwidth}P{0.2305851063829787\textwidth}P{0.14015957446808508\textwidth}}
Material\tabcellsep Outlet velocity m/s\tabcellsep Outlet mass flow rate Kg/s\tabcellsep Thrust (N)\\
ABS\tabcellsep 12.50\tabcellsep 0.041\tabcellsep 0.51\\
PLA\tabcellsep 10.30\tabcellsep 0.032\tabcellsep 0.33\\
Wood-fill/PLA\tabcellsep 11.91\tabcellsep 0.039\tabcellsep 0.465\\
Glass fibre fill/PLA\tabcellsep 12.94\tabcellsep 0.044\tabcellsep 0.57\\
Bronze-fill/PLA\tabcellsep 13.96\tabcellsep 0.049\tabcellsep 0.68\end{longtable} \par
 
\caption{\label{tab_1}Table 2 :}\end{figure}
 			\footnote{Experimental and Simulation Performance for Fan Extraction System© 2017 Global Journals Inc. (US)} 			\footnote{© 2017 Global Journals Inc. (US)} 			\footnote{© 2017 Global Journals Inc. (US) Image shows Manometer is connected without fixing the ends, which cause vibrations} 		 		\backmatter  			  				\begin{bibitemlist}{1}
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\bibitem[Kaminsky et al. ()]{b1}\label{b1} 	 		‘CFD study of wind turbine Aerodynamics’.  		 			C Kaminsky 		,  		 			A Filush 		,  		 			P Kasprzak 		,  		 			W Mokhtar 		.  	 	 		\textit{Proceedings of ASEE North Central Section Conference},  				 (ASEE North Central Section Conference)  		2012. American Society for Engineering Education.  	 
\bibitem[Kaewnai et al. ()]{b2}\label{b2} 	 		 			S Kaewnai 		,  		 			M Chamaoot 		,  		 			S Wongwises 		.  		\textit{Predicting performance of radial flow type},  				2009.  	 
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\end{document}
