Mixed flow fan is a kind of widely used turbomachine, which has faced problems of further performance improvement in traditional design methods in recent decades. Inspired by the microgrooves such as riblets and denticles on bird feathers and shark skins, we here propose biomimetic designs of various blades with the bio-inspired grooves, aiming at the improvement of the aeroacoustic performance. Based on a systematic study with computational fluid dynamic analyses, we found that these designs had the potential in noise suppression even with macroscopic grooves. Our best design can suppress turbulence kinetic energy by approximately 38% at the blade leading edge with aerodynamic efficiency loss of only 0.3 percentage points. This improvement is achieved by passive flow control. The vortical structures are changed in a favorable way at the leading edge due to the grooves. We believe that these biomimetic designs could provide a promising future of enhancing the performance of mixed flow fans by making grooves of ideal flow passages on the suction faces of blades in accord with the theory of pump design.

Leading-edge (LE) noise is a common source of broadband noise for fans that can be suppressed using appended LE serrations. We conduct an integrated study of the morphological effects of interval, length, and inclination angle of owl-inspired LE serrations on the aeroacoustic characteristics of a mixed flow fan using experiments, computational fluid dynamics (CFD), and the Ffowcs Williams–Hawkings (FWH) analogy. A novel method for surface noise strength (SNS) visualization was developed based on the FWH analogy with large-eddy simulations to accurately quantify the spatial distributions of acoustic sources. A CFD-informed index is proposed to evaluate the severity of flow separation with the pressure gradient and verified to be effective in examining the chord-wise separation. Acoustic measurements show the robust trade-off solving capability of the serrations under various morphologies, and the SNS visualizations indicate that the separation-induced LE noise is suppressed considerably. One-third octave analyses suggest that extending serration length can lower separation noise more effectively than shrinking the interval over 100–3000 Hz. A smaller interval is more desirable while an optimal length exists in association with tonal noise. Moreover, small inclination angles ([Formula: see text]) enable the deceleration of oncoming flows with stagnation relieved, and consequently, further suppress the LE noise, by a flow-buffering effect. Heavy inclination angles ([Formula: see text]) induce an additional tip vortex, causing high-coherence turbulence impingement noise and resulting in a drastic increase in broadband noise at frequencies exceeding 4000 Hz. Our study, thus, clarifies the morphological effects of LE serrations on aeroacoustic signatures of rotary devices while providing useful methods for acoustic analyses.

There is an increasing need in industry for noise reduction in fans. Inspired by owls' silent flight, we propose four owl-inspired blade designs for a mixed-flow fan to examine whether leading-edge (LE) and/or trailing-edge (TE) serrations can resolve the tradeoff between sound suppression and aerodynamic performance. We investigate the blades' aeroacoustic characteristics through various experimental methods and large-eddy simulation (LES)-based numerical analyses. Experimental results suggest that 'slotted', simply-fabricated LE serrations can achieve a lowering of the noise level while sustaining the aerodynamic performance of the fan, whereas TE serrations fail. In addition, the inclination angle can improve LE serration performance in aeroacoustic and aerodynamic performance with a reduction in the specific noise level by around 1.4 dB. LES results and noise spectral analysis indicate that the LE serrations can suppress flow separation, reducing the broadband noise at low-to-middle frequencies (40-4k Hz). This passive-flow-control mechanism, likely due to local higher incidence angles associated with LE serrations, is capable of alleviating the intensive pressure gradient while suppressing wall-pressure fluctuations over the LE region, hence weakening the Kelvin-Helmholtz instability. The tonal noise also shows a marked reduction at the highest peak frequency associated with fan-vane interaction. Moreover, we find that the high-frequency noise by-product radiates mainly from the LE serrations andsurroundings, due to the small eddies broken up when the vortical flows pass through the LE serrations. Our results demonstrate that the biomimetic design of the LE serrations can facilitate the break-up of LE vortices passively and effectively without negatively impacting aerodynamic performance, which can be utilized as an effective device to improve the aeroacoustic performance of fan blades.