Improving Fan Conception to Get the Expected Performance

Rodrigo BENEVIDES

Senior Simulation Engineer

Valeo Powertrain Thermal Systems – La Verrière (France)

6th European Altair Technology Conference – April 2013

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The Valeo Group

Global Presence

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The Valeo Group

Climate Control

Powertrain Thermal Systems

Climate Control Compressors

Front-End Modules

4 Business Groups

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Introduction

Motivation

Modified shape of fans in rotation can change its efficiency

Objective

Deformed Shape when rotating = Designed Shape to reach Expected Performance

Structural Simulation

Stiffness Anisotropy

Rheology-Structure Coupling approach

Methodology

Mesh treatment for structural simulation

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Fan Performance

CFD Simulation

Design for Expected

Performance

When Rotating Fan should have the Shape of CFD Conception

Deformed Fan when

Rotating

Efficiency

Reduction = - 5%

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Reinforced Plastics Stiffness

injection g

ate

plate

Tensile test samples:

45°

90°

0°

Stiffness depends on the orientation of fibers

Specimen tested at 23°C, RH50

0

20

40

60

80

100

120

140

0 0,02 0,04 0,06 0,08 0,1 0,12

Engineering strain

En

gin

ne

rin

g s

tre

ss

(M

Pa

)

0

45

90

Tensile Tests

90° 45° 0°

Strain

Str

es

s

(Thickness

direction)

Fibers

E In-Flow > E Cross-Flow > E Thickness

E = Young modulus

Anisotropy:

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Application

Orientation

of Fibers

Injection Molding

Simulation

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Material Model Effect

Displacement of Fan Under Rotation

Isotropic Material Model

Anisotropic Material Model

Isotropic models can not be used

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Update Geometry

yes

Deformed Shape =

Expected Shape ?

Deformed from

Starting Geometry

Treated Mesh

Deformed from

Treated Mesh

Second

Treated Mesh

Deformed from

Second Treated Mesh

Displacement

scale = x5 Rheology (injection)

Structural (rotation)

coupling

Starting Geometry

Mesh Shape

Treatment: (Before – After) Deformation

no

Methodology

Mesh Treatment is the key

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Mesh Shape Treatement

HyperView

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« Before » model results file

« After » model results file

Mesh Shape Treatement

HyperView

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Next Steps

Add the air pressure load on the structure for each treated mesh

To test different levels of mesh density

FEA Mesh CFD Mesh

Special thanks to:

Manuel HENNER (CFD Expert and CFD Department Manager)

Bruno DEMORY (CFD Expert)

Do you have questions?