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Abstract In this work, a methodology for propeller fan optimization using the three-dimensional inverse design method is presented. The workflow is demonstrated through the optimization of a previously designed propeller fan, the performance of which has been numerically and experimentally studied. The vortex distribution, the pressure loading on the blade surface and the stacking were varied during the optimization. The 3D blade geometries were obtained from the inverse design calculation, which can explore a large design space with relatively small amount of input parameters. This leads to some advantages when using a design of experiments (DOE) approach. The aim is to improve the aerodynamic performance of the fan. Meanwhile, the noise level should be kept under control. A multi-objective optimization was carried out based on the DOE results to find the balance between conflicting objectives. An optimum design was picked from the optimization. The performance of the optimized design was then verified by computational fluid dynamics simulations. The results show an increase of peak efficiency and pressure rise. The low flow rate performance is also improved. The flow physics that led to the performance improvement are discussed based on the numerical results. The same optimization workflow and principles can be applied to other types of axial fan as well.
Zhang et al. (Mon,) studied this question.