The effect of rotational speed and pressure rise on the leakage flow noise radiated by a low-speed axial fan, provided with rotating shroud, has been systematically investigated. The flow in the gap region has been studied by means of particle image velocimetry (PIV) measurements taken in the meridional plane. At low blade loading, the leakage flow is restrained close to the rotor ring and, at higher loading, it forms a wide recirculation zone. In the latter conditions, an unsteady flow separation likely takes place in the blade tip region which may be observed in the instantaneous flow field only. The leakage flow noise generally increases with the blade loading, but is non-monotonic, as the overall sound pressure level (OASPL) growth is interrupted by local minima; such a trend is qualitatively independent of the rotational speed. As the loading increases, the sound pressure level (SPL) spectrum shows important modifications, since the characteristic frequency of the subharmonic narrowband humps related to the leakage noise decreases; furthermore, height and width of the humps vary non-monotonically. Such a complicated behavior is likely related to the modifications in the leakage flow pattern and also to the appearance of the flow separation at the blade tip.

The present paper reports a 2D-PIV (particle image velocimetry) study of the effect of the operating point on the leakage flow in a low-speed ring fan. First, the flow pattern has been studied at 12 operating points covering the whole characteristic curve. At very low loading, the leakage flow streams along the rotor ring and is directly reingested; then, a separation bubble attached to the ring forms that, approaching the design point, modifies in a flow streaming radially outward. As the loading further increases, a separated flow region appears in the blade tip region that finally merges with the leakage flow. A further, more detailed study has been performed at eight operating points in the neighborhood of the design one. Very small loading variations may yield the leakage flow pattern modification, but no intermittence is present during the transition, as instantaneous flow patterns of any intermediate type continuously alternate. These results provide a consistent explanation for the ones of previous acoustic measurements.

The present work reports an experimental study of the leakage flow in a low-speed fan ring. Existing 2D Particle Image Velocimetry (PIV) measurements taken in a meridional plane in front of the rotor gap have been further processed and analyzed by means of the Proper Orthogonal Decomposition (POD). Three values of the dimensionless pressure rise across the rotor have been investigated. Namely, attention has been focused on the intermediate case—the one for which a strong radial oscillation in the leakage flow has been observed: POD results have shown that, in this condition, the leakage flow exhibits periodic radial oscillations that are not correlated to the periodic blade passing. Moreover, such coherent motions have been found to promote turbulence transport at different radial positions, whereas rotor-related oscillations have a negligible effect in this sense. The present POD procedure can be generally applied to turbomachinery flows to characterize their unsteady behavior beside the classical phase-averaging methods based on rotor-related quantities. The present approach is novel for the study of leakage flow dynamics in axial fans.

This work presents an experimental study of the effect of blade count on the flow field and the radiated noise in a low-speed axial fan with a rotating shroud. A two-component Laser Doppler Velocimetry (LDV) system and Particle Image Velocimetry (PIV) instrumentation have been employed to investigate the flow in the gap region and in front of the rotor blades. Additionally, the fan has been installed in a hemi-anechoic chamber and far-field acoustic measurements have been taken with a microphone mounted on-axis upstream of the rotor to show changes in the spectral features of the radiated noise. The tested rotor is a variable-geometry one that has allowed for studying rotor configurations with different numbers of blades of the same chord and shape, i.e., of the same geometry but different solidity. Rotor pressure rise and flow rate are average quantities that have a relevant effect on the leakage flow. Keeping them fixed while varying solidity allows us to highlight the local effects of circumferential pressure non-uniformity caused by differing blade loading. The results show that, at low solidity, the flow leaving the gap is mainly directed radially outward and follows a longer path before being ingested by the rotor, thus losing strength due to mixing with the main flow. As solidity increases, the flow becomes less radial and is more rapidly ingested by the rotor. In all cases, the sound pressure level spectrum shows marked subharmonic humps and peaks originating from the interaction between the leakage flow and rotor. The departure of such peaks from the blade passing frequency increases with the solidity, while the associated energy increases up to seven blades and then decreases.

This paper presents a numerical investigation of the effect of rotational speed on the development of leakage flow in a low-speed axial fan equipped with a rotating shroud. Rotor deformation induced by centrifugal forces and aerodynamic loading is taken into account through a one-way coupling between steady CFD simulations and static FEM analyses. Aerodynamic and structural results obtained at four rotational speeds are validated against available experimental data collected by the same research group, and the different leakage flow patterns associated with rotor deformation are correctly reproduced. Subsequently, the deformed geometries corresponding to two rotational speeds and operating at the same non-dimensional flow coefficient are used to perform URANS simulations. The numerical results provide insight into the leakage flow behavior within the gap between the rotating shroud and the stationary casing, a region that cannot be experimentally investigated due to optical access limitations. It is shown that the leakage flow rate through the gap shows limited sensitivity to rotor deformation, as it scales with rotational speed, and it is fed by two main contributions: a flow directly extracted from the rotor outlet and a recirculating flow developing along the mounting panel. Conversely, the non-dimensional angular momentum flow rate is larger at the lower rotational speed, corresponding to the case in which the leakage flow is rapidly re-ingested by the rotor. This indicates that the centrifugal effects associated with the leakage flow swirl are not responsible for the observed change in leakage flow pattern. Finally, significant periodic and non-periodic components are identified within the leakage flow. These components are expected to contribute to the formation of the large-scale structures impinging on the rotor blades and thus generating significant noise.