Manufacturing of Composite Radiator Fan

IJIRST –International Journal for Innovative Research in Science & Technology| Volume 4 | Issue 4 | September 2017 ISSN (online): 2349-6010

Manufacturing of Composite Radiator FAN S. U. Misal PG Student Department of Mechanical Engineering DKTE’S TEI Ichalkaranji, Maharashtra, India

G. S. Joshi Professor Department of Mechanical Engineering DKTE’S TEI Ichalkaranji, Maharashtra, India

V. R. Naik Professor & Head of Dept.

Department of Mechanical Engineering DKTE’S TEI Ichalkaranji, Maharashtra, India

Abstract The radiator fan is a device, which sucks the atmospheric air through the radiator panels and expels it to atmosphere to cool the engine coolant after discharge from the engine and maintains an acceptable operating temperature by transferring heat from the engine to the atmospheric air. The cooling fan are part of the cooling system and their design to keep a cooler temperature in the engine. A composite material is a material consisting of two or more physically or chemically distinct phases. The composite generally has superior characteristics than those of each of the individual components. There is an increasing demand for advanced materials with better properties to meet new requirements or to replace existing material.

Keywords: Radiator FAN, Composite Radiator FAN _______________________________________________________________________________________________________ I.

INTRODUCTION

Composites are compound materials, differ from alloys in the fact that individual components retain their characteristics but are so incorporated into composites so as to take advantages only of attributes, not that characteristics of short comings, to obtain improved materials. The individual components remain separate and distinct within the finished structure. Properties of composites are strongly influenced by the properties of their constituent materials, their type, their distribution and the interaction between them. Like conventional materials, composites are not homogeneous and isotropic.

At present aluminum is widely deployed in blade manufacturing mainly due to the advantages such as less density compared to steel, corrosion resistance and aesthetic look. Though aluminum has wide advantages when compared to steel, it stays back in certain properties such as less strength to weight ratio, paint coating etc. Composites have become a better replacement for conventional steel with adequate improvement of mechanical properties and their reduced weight. But in actual practice, improper heat treatment of the radiator fan blade, Pressure variations along the length of the blade due to this material is failed.

Though a variety of resins and fibers are available, considering the manufacturing easiness and the mechanical aspects epoxy resin and E- glass fibers is employed in the fabrication work. The term epoxy refers to a chemical group consisting of an oxygen atom bonded to two carbon atoms that are already bonded in some way. Epoxy resin is almost totally transparent when cured. EGlass fiber has good tensile and compressive strength.

II. FUNCTION OF RADIATOR The Radiator performs the function of cooling, the coolant which has passed through the water jacket and become hot, and it mounted in front of the vehicle. The radiator consists of upper tank and lower tank, and a core which connects the two tanks. The upper tank contains an inlet for coolant from the water jacket and a filler inlet. It also has a hose through which excess coolant can flow. The lower tank has an outlet and drain cock for the coolant. The core contains many tubes and cooling fins through which coolant flows from the upper tank to the lower tank so that coolant has been heated up as it passes through the water jacket is cooled by the air sucked through the radiator by the cooling fan.

III. RADIATOR FAN The engine produces power by converting chemical energy of fuel into heat energy by combustion. Part of total heat produced by the combustion is used to push the piston downwards and thereby producing necessary power. Some of heat is carried away by the exhaust away by the exhaust gases through the exhaust valve. The remaining heat is absorbed by the engine itself, which increase its temperature. The heat of the engine is absorbed by the coolant in order to bring the engine temperature within its normal operating range.

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Manufacturing of Composite Radiator FAN (IJIRST/ Volume 4 / Issue 4/ 017)

A typical automotive engine cooling system consist of a radiator, fan, water pump, coolant, reservoir, thermostat, heater core and necessary plumbing for both the radiator and heat core. When the engine is started, the water pump connected to it also begins to pump the coolant around the engine cylinder from the lower radiator tank into the coolant passage Cooling Fan The cooling fan provides additional cooling airflow when the ram airflow through the cooling system is too low. This situation occurs when the vehicle is climbing a hill at a low speed or in stop and go traffic. In fact a worst case design scenario is typically defined as a vehicle pulling a rated fully loaded trailer up a 5% grade with an ambient air temperature of 100 0 F (Oler and Williams, 2001). Consequently, fans are needed that are able to supply a high volume of cooling air into a high pressure loss system at high efficiency, low weight, and with low noise (Hucho, 1998). To meet this design criterion, the typical cooling fan has undergone a complete redesign and optimization as compared to the typical stamped metal cooling fans of the past.

Power requirements for engine cooling can be reduced by improvements in radiator and fan design. In addition, more effective engine cooling is possible by properly matching the ram air and the cooling fan.

IV. MANUFACTURING PROCESS Glass fiber epoxy material fan is manufactured by Hand lay-up process. For the manufacturing the resin used is Polyester resin 150. This resin contains high tensile strength and flexural strength. Also, the blades are free from blow holes, pin holes, porosities.

It provides a highly smooth surface finish. This smooth surface finish helps reduce the frictional loss of air passing through the fan blades. Thereby increasing overall efficiency.

Hand Layup Process for Glass Fiberrain-forced plastic (Epoxy) as follows: Preparation of the Mold Remove dust and dirt from mold. If mold is of plaster, wood, or new fiberglass, apply soft wax and buff with soft towel. Spray or brush with PVA, parting compound and allow drying. If mold material is glass, metal, ceramic, or well-cured fiberglass, apply three coats of hard wax, carnauba type, buffing between each coat.

Applying the Gel-Coat If gel-coat is to be brushed on, allow first coat to cure and then apply the second coat to make sure that there should be no light spots. If gel-coat is to be sprayed on with a gel-coat gun, spray up to a thickness of .015” to 020”. When gel-coat has cured long enough that your fingernail cannot easily scrape it free (test at edge of mold where damage will not show on part) then proceed with next step.

Lay-up Skin Coat Cut ¾ or 1 mat to cover part. Brush catalyzed resin over gel-coat then applies the mat. Work with roller adding more resin where necessary until all white areas in mat fibers have disappeared and all air bubbles have escaped. Resin-rich areas weaken the part.

Where rollers will not reach, brushes must be used. When this step is complete, clean all tools in acetone. Allow skin coat to cure before next step.

Trim On a small lay-up, the fiberglass laminate which hangs over the edge of the mold can be trimmed off easily with a razor knife if you catch the “trim stage,” of the period after the lay-up has gelled but before it has hardened. On a larger lay-up, it can be trimmed with a saber saw and coarse sand paper.

Cure Cure may take from two hours to overnight, depending upon turnover desired, temperature, canalization, and nature of the part. If laid up in a female mold, longer cure will affect shrinkage and easier parting. In the case of the male mold, the part comes off more easily before it shrinks appreciably. If the part is subject to warping, a longer cure may be necessary. In any case, when the part is removed it should be supported in its desired shape until fully cured.

Remove Part from Mold First, examine the trim edge all the way around the mold and make sure there is no resin bridging the line between the mold and the part. Sand this edge where necessary. Then wooden wedges, such as “tongue sticks,” can be pushed into the edges to start the separation. Continue separation by pulling and flexing. In somecases, it is necessary to drill a small hole in the mold and apply air or water pressure.

Finish Trim edges and back of part may need to be fine-sanded and coated with surfacing resin or gel coat.

For manufacturing Radiator fan two main parts are important: Fan Hub and Fan Blades.

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Manufacturing of Composite Radiator FAN (IJIRST/ Volume 4 / Issue 4/ 017)

Procedure for Manufacturing Hub 1) According to design prepare the mold for hub.

2) Prepare the mold for 100 mm diameter of hub. Remove dust and air from mold.

3) Applying the gel-coat to the part. Allow the first coat to cure and then apply the second coat to make sure that there should be no light spots.

4) Brush catalyzed resin over gel-coat then applies the part by roller to reduce air bubbles.

5) Then laying the polymer resin 150 and mixing of cobalt and liquid hardener.

6) On a small lay-up, the fiberglass laminate which hangs over the edge of the mold can be trimmed by razor knife.

7) For cure the part take time more than two hours.

8) First, examine the trim edge all the way around the mold and make sure there is no resin bridging the line between the mold and the part. After that remove the part from the mold.

9) Then fine finishing of the part need.

Fig. 1: Mould for Fan hub

    

Material: Glass Fiber Epoxy Reinforced Plastic Shape: Cylindrical - Shell Mass: 150gm Minimum Section Thickness: 4 MM Tolerance: ± 1 MM

Fig. 2: Finished Fan hub

Procedure for Manufacturing Blade          

We took the standard 6 blade fan available from market.

Cut the blades for the mold.

Prepare the mold for 6 mm thickness of blades. Remove dust and air from mold.

Applying the gel-coat to the part. Allow the first coat to cure and then apply the second coat to make sure that there should be no light spots.

Brush catalyzed resin over gel-coat then applies the part by roller to reduce air bubbles.

Then laying the polymer resin 150 and mixing of cobalt and liquid hardener.

On a small lay-up, the fiberglass laminate which hangs over the edge of the mold can be trimmed by razor knife.

For cure the part take time more than two hours.

First, examine the trim edge all the way around the mold and make sure there is no resin bridging the line between the mold and the part. After that remove the part from the mold.

Then fine finishing of the part need.

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Manufacturing of Composite Radiator FAN (IJIRST/ Volume 4 / Issue 4/ 017)

Fig. 3: Mould for fan Blade

    

Fig. 4: Final product back side

Front side Material: Glass Fiber Epoxy Reinforced Plastic Shape: Aerofoil Shape Mass: 50gm Minimum Section Thickness: 6MM Tolerance: ± 1 MM

Fig. 5: Final assembly of Fan

V. CONCLUSION By referring above simple hand lay up processs it is very easy to manufacture composite radiator fan. By adding screw and nut attachment at the base of blades we got further advantage of inclination of blade for more air velocity and discharge. The composite fan gives the high airflow, reduces weight, minimizes unbalanced forces and improves cooling performance for radiator.

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