Improved method of manufacturing automotive cooling fan blades by centrifugal casting method

Abstract

The axial fans mentioned in this study are used in automobile cooling systems. This is a relatively vibrant industrial market today. Therefore, there is a need for more research and application of solutions to improve the product. Previously, these fans were often manufactured by injection molding, mechanical processing or heat pressing. However, the material market is currently relatively developed, the cost is relatively cheap, so it is necessary to consider and improve the manufacturing method of parts and components. Centrifugal casting technology was developed in the early years of the 20th century. This is a completely different casting method compared to traditional methods. The characteristic of this method is to create hollow casting products due to the impact of centrifugal force. The study presented the method of constructing axial fan blade profiles on MFT calculation software and 3D design software (NX). Based on some studies, the modified structure of the fan blade, the blade versions with thickness of 4 mm, 10 mm and the mold were designed. The fan blades were aerodynamically tested on the ISO 5801 standard test bench including: aluminum fan with blade thickness of 4 mm, 10 mm (reference fan) and fan manufactured by centrifugal casting method. The research results show that the curve trend obtained by centrifugal casting fan blade is almost similar to the reference fan blade. At the design point of axial fan blade, the maximum efficiency corresponding to the rotation speed n = 2000 r/min is: 45.2% (centrifugal casting fan blade), 42,3% (10 mm fan blade), and 46.9% (4 mm fan blade), respectively. The results show the adaptability of centrifugal casting process to manufacture axial fan blade. However, to improve the efficiency of this type of fan blade, more in-depth research is needed to evaluate the factors affecting the performance as well as other benefits that this manufacturing method brings.