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A numerical method was developed to establish a procedure for an axial flow fan design. Theory of free/force vortex motions, boundary element methods and optimization methods were applied to conduct this process. Rotational speed, ambient temperature and pressure were used as the input data; and tip diameter, hub diameter, number of blade, flow rate, static pressure, and vortex motion were initially guessed and employed to compute the design parameters. These design parameters included lift and drag of an airfoil profile, inlet angle and velocity, outlet angle and velocity, and variation of axial velocity in the radial direction. The optimization of tip diameter, hub diameter, number of blade, chord, and stagger angles at different radii were calculated as the numerical results. Computational solutions of the stagger angles in the radial direction were compared with those of the Valeo's current products. Agreement of the comparison of the stagger angle is reasonable.

A numerical process, which consists of free or force vortex motion, boundary element methods and optimization methods, was developed to calculate the design parameters of an axial flow fan. Rotational speed, tip and hub diameters, and number of blade were used as the input data. Stagger angle, radial varation of the blade angles, was calculated with this numerical process. Sum of the difference of the stagger angle for numerical solution and that for current design was minimized by using the optimization methods. Parameters of the computational solution, including lift and drag of an aerofoil, inlet flow angle and velocity, outlet flow angle and velocity, and variation of axiaI velocity in the radial direction, were calculated to investigate the current product of axial flow fan. Three cases were run to validate the numerical solutions. Case A and case B were the Valeo's current products; case C was the Valeo's prototype fan.