Porous trailing edge for airfoil and fan noise reduction at low-speed stall conditions
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Airfoils employed in rotary systems such as wind turbines, helicopter rotors and cooling fans can generate significant levels of noise due to boundary layer instabilities and turbulent eddy interaction. At lower sound intensity and shorter exposure, this noise can be perceived merely as a source of annoyance, however, prolonged exposure can lead to serious health implications. Fan noise is present in various aspects of daily lives, such as automotive, Heating, Ventilation, and Air Conditioning (HVAC) system, and electronic cooling, but despite its prevalence, research in the noise generation and reduction mechanisms are limited. The increasing demand for cloud-memory storage and high-performance computing (HPC) requires increased cooling requirements, consequently elevating noise levels in data centers. While conventional soundproofing techniques have been effective, novel modifications to airfoils offers passive aeroacoustics noise reduction through control of the noise source. One approach involves applying porous treatments to the airfoil's trailing edge which has demonstrated good noise reduction capabilities at low angle of attack. Experimental testing in anechoic wind tunnels is expensive and measurements within the porous medium are challenging. Alternatively, Computational Fluid Dynamics (CFD) can provide a detailed representation of the flow field of the internal pore topology, however at high Reynolds number, pore-scale simulations are computationally demanding, and a volume-average approach is typically utilized. Due to these challenges, the mechanism of noise reduction of a porous trailing edge is not fully understood and airfoils at stall conditions have not been explored. This study adopts a hybrid approach combining numerical simulations and experimental methods to gain a comprehensive understanding of the flow dynamics and its application for low-speed axial fans. Wall-resolving Large-Eddy Simulations (LES) utilizing the WALE model are conducted on porescale meshes of a commercially utilized airfoil designed for cooling server racks. Gyroid-shaped unit cells with an average pore diameter of 1 mm are applied from the half-chord to the trailing edge and the partially porous airfoil is compared to its fully solid counterpart under stall conditions. Preliminary numerical results highlight changes to the Reynolds stresses and the height of the shear layer which can be attributed to the pressure gradient within the porous media across the suction and pressure side of the airfoil. To ensure the accuracy of the CFD results, the study will conduct wind-tunnel experiments at the WSU 3x4ft Wind Tunnel to validate lift and drag coefficients. The airfoils are 3D printed with circular end plates to minimize tip vortex effects. Furthermore, to demonstrate the noise reduction properties in an industrial setting, electronic cooling fan models are fabricated with and without porous treatment and the noise levels were recorded in a semianechoic recording studio at Shocker Studios. Preliminary experimental results have shown reductions up to 3dB compared to conventional fan designs.
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Research completed in the Department of Mechanical Engineering, College of Engineering.
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v. 20

