Numerical Analysis of a Five-Bladed Axial Fan Using Computational Fluid Dynamics (CFD): A Comparative Study for Aerodynamic Design Optimization

A numerical study of an axial fan was conducted, with models compared to catalogue data, key results discussed, and performance improvement suggestions proposed. Research aims to numerically analyze a five-blade axial fan, using topology optimization to maximize flow rate and minimize blade count by comparing fans with varying blades to identify the optimal design. The five-blade axial fan was designed using Creo PTC Software based on standard requirements, and its numerical analysis was conducted using Computational Fluid Dynamics in ANSYS Workbench (2022 R1). The simulation results for the five-blade fan were validated against catalogue data and compared with fans having 1-7 blades. Results, presented through various contour plots and velocity streamlines, showed that the maximum airflow rate (ṁ = 1.432 kg/s) occurred with four blades, the highest-pressure contour (T total = 474 kPa) with six blades, and the highest total pressure contour (T total = 170 kPa) at the hub with three blades. The maximum velocity contour (V= 30 m/s) and velocity streamline at the stationary frame (V= 35 m/s) were recorded with five blades. Overall, comparing the four-blade results with the other cases shows that the four-blade configuration delivers superior performance under the same model setup and can be used to enhance future designs.