ME 424 ENGINEERING DESIGN VII

PHASE VI – PERFORMANCE TESTING AND DESIGN

IMPROVEMENT

DESIGN & DEVELOP OF AN ICING WIND

TUNNEL

A SENIOR DESIGN FINAL REPORT

GROUP 1 4:

ELIE FONROSE
ERSHAUN HARRIS
FATIIMAH NAAMAT
JEREMY NIRMAL
MARCEL IPINCE

ADVISOR PROF. C. H. CHOI

“ We pledge our honor that we have abided by the Stevens Honor System”

STEVENS INSTITUTE OF TECHNOLOGY

Castle Point on Hudson
Hoboken, NJ 07030

(May 1st, 2009)

 Special Dedication
This project is dedicated in memory of
Elie Fonrose

21 March 1984 - 10 April 2009

2|Page
Table of Contents

3|Page
Abstract 4
Executive Summary 5
Design Specifications 6

Summary of Phase I 7
Summary of Phase II 9
Summary of Phase III 14
Summary of Phase IV 18
Summary of Phase V 20

Phase VI 23
Design Improvements 23
Fabrication Process and Concerns 27
Testing 36
Safety Issue 43
Cost Summary 44
Future Considerations
48
Conclusion

Appendix 49
Pictures of IWT
49
Design Implication
51
Nugget Chart
52
Gantt Chart
58
List of References
59

4|Page
Abstract
Wind tunnels are used in different industries. The aerospace, aviation and
military all have their own wind tunnels. These wind tunnels are full scale ones
which take up the space of buildings. Tests for different conditions are conducted
within these large wind tunnels on life size test samples. These wind tunnels are
of great importance as they test for all safety issues which affect these airborne
vessels. Among the many concerns for safety, on major concern is that of icing.

Icing is a problem which affects the aerodynamics of flight. It causes

increased drag and a loss in lift. In extreme conditions, this could lead to
accidents. In this project, the team will attempt to build a small scale Icing Wind
Tunnel (IWT). This tunnel will be modeled based on full scale wind tunnels and
will replicate icing conditions similar to those outside an aircraft in flight. If icing
conditions are successfully created, the group will test airfoils for advanced
materials which could be used to prevent icing on aircraft.

5|Page
Executive Summary

In this project, we are attempting to build a small scale Icing Wind Tunnel (IWT).
The IWT will generate icing conditions similar to the conditions an aircraft
experiences during flight. By acquiring the correct environmental conditions
inside the tunnel, we were able to see/study ice accumulation inside our IWT.

6|Page
Design Specifications

Specifications
Wind speed at the test section 50 mph
Test section crossed section area 10 inch x 10 inch
Lowest temperature -10 degree Fahrenheit
How it works
1). Let the evaporator and fan run until the desired temperature reached
2). Turn on water nozzle system
3). Ice buildup on the specimen inside the test section

7|Page
 Summary of Phase I
For phase I, we encountered confusion in determining the project
objective. Our first objective was to design and develop a small scale Icing Wind
Tunnel (IWT) and do research about icing accumulation on the aircraft. After our
first presentation, we came to realize that the main objective in our project is to
build and develop a small scale wind tunnel. However, we now have better
understanding of ice accumulation and prevention, and the results of severe ice
accumulation. That knowledge helped us fulfill the requirements of our project.
During Phase I, we brainstormed and came up with many ideas on how we
would design our IWT. We went through different designs that already exist in
the market.
Figure
Figure
32 –1 A2
– Cox
Wind
andTCompany
unnel (inside
at Mooresville,
(inside
North Carolina view)
view)
Figure 1.a – Different types of wind tunnel

Everyone threw out their ideas and

we discussed it. Finally, we wanted to have
an IWT that lay down flat on the floor, and
the dimensions were: maximum height - 12
ft, length – 10 ft and width – 5 ft. We built a
Solidworks model of our design.

Figure 1.b – The first draft

The advantages of a small scaled IWT are less energy required for cooling
the temperature down, low operation cost, and low construction cost to produce
the same results as other large scale IWT.

We planned our technical analysis and engineering for the next phase. The
calculations that should be done to support our technical analysis are

8|Page
  Air Pressure/Temperature/Velocity
 Lift/Drag
 Efficiency of Main Components
 Density of Saturated Water Vapor (ideal/present)
 Weight of Water passing (per second)
 Water Drop Radius
 Water Vapor Diffusivity
 Area of Model (after type of cooling process is chosen)

Those calculations are needed to determine the type of refrigerant, fan,

water nozzle, frame dimensions and other components. At the same time, we
were thinking of doing 3D analysis using Solidworks, CosmosMotion or other
Auto CAD software.

Type Testing Purpose

Parameter
Fluid Fan/Motor Capability of producing required fluid flow
Testing Area Reduce drag and optimize flow in testing area

Structural Materials Preventing structural failure

Selection
Joining Method Capability of supporting load and fluid forces
Corner Design Optimizing passage/Reducing fluid forces on
joints

Thermal Refrigeration Capability of producing require temperature

Unit
Material Selection Preventing thermal failure
Heat Exchanger Efficiency of controlling fluid conditions
Table 1.a

We were hoping that at the end of the semester, we would have all the
analytical calculations, figuring out the required components and 3D analysis
results.

9|Page
Summary of Phase II
Phase II started with decisions on component location. We had two ideas
about where the components should be located. We proceed to the new design as
shown below for the advantages that it has.

Old Design New Design

Test Section
Water
Spray

De-icing
Drawing mechanism

Fan
Turning Evaporator
Vane

Comparison • two freezers • the fan is before the

• small pipe for continuous refrigeration system
air flow • turning vane at each corner
• fan and water nozzle in • longer test section
the freezer

Table 2.a

We also revised our conceptual design from Phase I. Compared to Phase I,

the IWT now standing up on the floor instead of lying down. The main reason for
this change is that if we were to proceed with the old design, we would get an
IWT with more than 5 ft width, which exceeds our design requirement.

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Old Design New Design

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 We determined the dimensionsof each section of IWT by using the method
of trial and error with the contraction ratio of 8:1 and fixing the test section area
of 8” by 12”. At the same time we tried to make a symmetrical IWT for assembly
simplicity and calculation’s ease. Below are the final dimesnions.

Description
– Symmetrical
– Standing up on the ground
– Length 8.583 ft
– Tall 4.5 ft

As discussed in Phase I, we added

Technical Analysis in our Phase
II:-

a). Contraction Ratio

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 Increase mean velocity
 Reducing pressure losses
 High contraction ratio
 Reduce fluctuating velocity variation to a smaller fraction of a average
velocity.
b). Vapor Refrigeration System

Assumption –
.:. Control volume steady state
.:. All processes are internally reversible
.:. Compressor and expansion valve
operate adiabatically
.:. Negligible potential and kinetic
energy

Result -
.:. β = 7.43

c). Heat Exchanger Calculation

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 Assumption –
.:. Steady state conditions
.:. Ideal gas law

Result –
.:. n = 100 tubes
.:. L = 32 in
.:. dinternal = 0.25 in

d). Water Nozzles Calculation

Using the humidity ratio, number of nozzles required can be determined.

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Result –
.:. N = 4 nozzles

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 e). Thermal Resistance Network Analysis

This analysis is to determine which material provides the lowest Q for

ducting and insulation. As shown above, the Q value

Fiberglass HVAC

Outside Temp (oF) 65 65

Inside Temp (oF) 5 5

RTOTAL=(oF/(Btu/hr)) 1.87 4.98
Q (Btu/hr) = ΔT/R -32.0855615 -12.06

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Finally, after having results from various analyses, we picked out the best
components.

No. Item Picture Specifications Price

1. Ducting - HVAC Readily Available $900

Easy to
Customize

2. Turning Vane Can easily screw $262

to the wall

3. Fan 34 diameter Blade

$ 370
15100 CFM = 257
mph Motor
$ 365
Blade Motor 3hp motor power

4. Water Nozzle GPM – 72psi $106

5. Test Section Heated insulated $ 700

glass

6. Refrigeration Condenser
Unit $ 500

Compressor
$ 213

Pump
$ 503

Heat
Exchanger
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 $ TBD

TOTAL $ 3, 919

Summary of Phase III

Phase III began with rechecking our calculations and making adjustments to our
design. We wanted the cross section to be reasonably sized, and therefore we
chose an 8 inch by 12 inch cross section. From our research, the most commonly
used contraction ratio is between 6:1 and 12:1. chose an average ratio of 8:1.

Next, the group added in the individual components of the icing wind tunnel and
changed the design as needed to make everything fit. The new design changed to
become:

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For the fan, the following equation was used:

This equation told us that 6930 CFM is the minimum needed for 120 mph.
For the water nozzles, the main points the group considered were the droplets
size and the GPM of the Nozzles. After researching the topic, the group decided
ultrasonic nozzles were the best choice for our project, however it was way over
the allotted price range for water nozzles. Thus, the group chose to go with
misting and fogging nozzles.

Initial research for the test section led the group to look for heated glass but the
price range was far outside of their allowed budget. Therefore, the group
researched an alternative in the form of polycarbonate. It can withstand

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temperatures as low as -40F and is affordable. The overall design of the test
section was chosen to be the following:

Two types of insulation/ducting combinations were looked at. They were

the Fiberglass ducting with Polyethylene cover and Sheet Metal HVAC Ducting
with ultra-flexible foam rubber insulation. These were looked at due to the
following calculations the group performed:

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21 | P a g e
At the end of Phase III, the group had made many changes to the design. The
following is a solidworks model of the new design:

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Summary of Phase IV
After further research was conducted, the group determined that the ducting
surrounding the heat exchanger needed to be modified. Ice accumulation is one
of the major problems in the wind tunnel and to tackle this issue, more space will
need to be made around the refrigeration system. A larger size ducting will need
to be used in order to allow the cold air to pass more effectively around and
through the heat exchanger.
For the water nozzle design, the major task for this phase was to position the
nozzles properly in order to achieve the optimum water spray angle. The
following design was chosen:

For the test section, the group changed the design from four sheets connected
with a door made into one of the sheets to four sheets connected with one sheet

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on hinges allowing it to open. The design can be seen in the following solidworks
file:

The group then focused on electrical wire and settled on a product sold by
BRISKHEAT. The product is an electrical wire that automatically adjusts its
temperature depending on the ambient temperature around it.

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Summary of Phase V
During Phase IV, the experienced major change in ducting. The ducting was
changed to round ducting as finally there was a company who was willing to do
the custom made round ducting. The round ducting would reduce turbulence in
the tunnel and therefore increase the efficiency of the air flow. At the same time,
turning vane was not required in this new design which means less cost for the
overall budget. The previous design was short in length which was about 10 ft but
the new design was 15 ft in length. The difference of two designed could be seen
below.

Figure 5.a Square Ducting

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Figure 5.b Round Ducting

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Other than that, the team changed the insulation from foam rubber to fiberglass
with aluminum jacket. This new insulation insulates heat better off than the
previous one.

Old Insulation New Insulation

R-Value (OF/hr-Btu) 2.7 10
Heat Loss (Btu/hr) 10.16 4.57
Table 5.a – Insulation comparison between foam rubber and fiberglass with
aluminum jacket.

Table 5.a showed that the new insulation had higher R-value. Also the new
insulation is professionally fabricated. Which meant it decreased heat loss and
has more controlled contractions.

The team made a closer analysis on the previous static pressure check and it
proved the system was unstable. The extrapolation assumption was flawed by a
volumetric flow rate cap through the evaporator coil. As a result, we used a
technique known as injection refrigeration. The idea was to create a refrigeration
loop to the free stream but allowing subtle mixing of streams.

In order for the injection system to work, we needed to add a damper into the
free system. Therefore, the resultant pressure drop forces some of the free stream
air into the external loop.

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Figure 5.c – The analysis of the injection system.

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Since the team changed the ducting, other components also needed to be
changed as well. The team made a change into the water nozzle system design.
The bar that hold the water nozzle together had to be longer than the previous
one.

Figure 5.d – Previous Design Figure 5.e – New Design

The team started placing orders for the components required. However, the fan
that the team had picked was not available so the team had to select different fan.
So the new cost one hundred dollar more and produce higher CFM than the old
one.

Figure 5.f – Fan with CFM 7920 and 3 phase line.

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With this new fan, the new air speed at the test section had to be calculated again.
The speed was determined to be 129.68 mph.

Based on the prototype schedule, the team predicted to start fabricating the IWT
early March and continue until April. The testing and analysis would be done in
the middle of April.

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Phase VI

A). Design Improvement

i) Ducting & Insulation

The Ducting is one of the key components of the IWT. In order for the
right conditions to be created within the tunnel, the Ducting needs to be strong
and have the best heat transfer properties. Cost however remains one of the
major constraints and keeping this in mind, the group selected the Ducting along
with appropriate insulation.

In Phase five of the project, the group had confirmed a tunnel design. This
design included round galvanized ducting, with a 24” diameter. The diameter of
the ducting needed to match that of the fan in order for air to fully develop and
maintain the desired velocity before reaching the Test section. A long contraction
was also added to contract the ducting from a diameter of 24” down to a cross
section of 9.5” x 9.5”.

When the ducting arrived, the team discovered that it did not match the
model drawing. The ducting that was delivered had a diameter of 12” as opposed
to the 24” diameter the team was expecting. The main reason for this was the size
constraints of the tunnel. The group had a constraint of 15 feet, and installing the
24” ducting at the corners would have resulted in the tunnel exceeding the 15 feet
constraint. In addition to the overall size of the ducting, the group also had the
tackle the new location of the contraction. In the original design, the contraction
was located at the test section. The size of the new ducting however was
compatible with the existing test section and therefore, a new contraction was
placed at the fan. This meant that the airflow was contracted to a smaller
diameter immediately after exiting the fan.

The new design of the ducting also meant that the orientation of the wind
tunnel needed to be changed. The ducting assembly now stood completely
horizontal and in turn parallel to the ground. This proved to be beneficial with
the airflow as the change in height was no longer a factor which affected the
volume of airflow.

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 Figure 6.a.i.a - 12 “ ducting with new contraction at fan

Figure 6.a.i.b - Secondary loop with refrigeration system

One aspect of the design which did not change was the Insulation. The
group had completed calculations for fiberglass insulation in phase 5. This
insulation had a higher k-value than the original foam rubber insulation. The
fiberglass insulation also fit within the budget of the foam rubber insulation. In

32 | P a g e
the final design, fiberglass insulation was used to maintain the cold conditions
within the tunnel. In addition to the insulation, PVC jacketing was wrapped
around the outer surface of the tunnel. The purpose of the PVC jacketing was to
avoid absorption of condensation into the fiberglass insulation.

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 ii) Refrigeration System
Sdfdsfgdgdf

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iii) Misting System
dfsdfsdf

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B). Fabrication Process and Concerns
i) Step by Step Process

1. The team started the fabrication process with making the frame of the test
section first.

2. Then the fan was connected to the HVAC contraction. Then the ducting
was connected together to make the whole of the IWT.

3. After that, the fiberglass insulation was installed on the ducting and
finished with PVC Jacket.

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4. The Liquid Nitrogen was stored in cryogenic tank. The Liquid Nitrogen
would be pumped through the copper evaporator with two inlets.

5. The works on the test section were continued with screwing the
polycarbonate glass to the frame. The team use hinges for the door
connection with the test section.

6. The simple misting technique was used to replace the water nozzle design.
The misting device could produce up to 80 micron water particle. The
moisture’s flow coming from the misting device was forced to get inside
the tunnel through pvc pipe. The pvc pipe was installed a foot away before
the test section.

37 | P a g e
 ii) Test Section Concerns

The fabrication process involved cutting, sawing, welding, and drilling. For
the angles, they were going to form the cross-section of the test section, so they
needed to be cut to eight ten inch pieces. From there, the excess corner on each
piece had to be cut off. Next, the four pieces had to be welded together to create
the cross section. While welding, the group took special care to follow all safety
precautions necessary when welding.

Next, the frame for the test section had to be made. Four thirty-three inch
angles had to be cut and then welded to each corner of the cross-section. After
this was complete, the group moved on to the polycarbonate sheets.

The group used the band-saw to cut the polycarbonate sheets to the
desired lengths. Once the new pieces were finished, they were placed along the
frame to prepare for the next step.

Next, the group marked the holes for drilling and then began to drill. Once
the drilling was complete for the non-hinged sides, the group screwed the
polycarbonate pieces to the frame. The group then marked holes for the hinged
side and began to drill. After screwing the hinge to the piece, the test section was
complete.

The group grew concerned that the frame would rust quickly but negated
this notion by spraying it to strengthen against rusting.

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 iii) Ducting & Insulation Concerns

The fabrication of the ducting was completed in co-ordination with the

Physical Plant department at Stevens Institute of Technology. The team used the
college’s provider for HVAC ducting to have the parts fabricated. The ducting was
manufactured at the ducting company’s manufacturing plant as individual parts.
These pieces of ducting were then transported to the college and assembled by
the ducting workers inside the fluids lab. The Ducting needed to be installed on
location due to the weight and size of the tunnel.

Figure 6.b.iii.a – The picture showed the look of IWT before and after assembly

One problem was encountered during the assembly of the ducting. This
had to do with the part of ducting where the round shaped ducting changed to a
square shape at the test section. While modeling this portion of the ducting, the
group had created a smooth transition in order to ensure that the air flowed
smoothly. The actual installation however was not a smooth one. As seen in the
picture below, the round to square ducting consists of a box which connects the
round and square sections.

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Figure 6.b.iii.b - Comparison of actual ducting to smoother transition in the
model

This was a concern because the box is larger than both the square and
round sections. A larger volume meant that there could be increased turbulence
in this section. This could be one of the reasons why the desired wind speed was
not reached.

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 iv) Misting System Concerns

After the decision had been made to switch to a new misting system, a plan
for installing the system needed to be developed. The best way to get the mist into
the tunnel without creating gaps that could cause any losses in cold air was to
make a hole about a foot before the entry of air to the test section.

The mister was placed in a container below the hole. The container was
completely covered with holes drilled for two components. The first component
to be inserted in the lid of the container was a PVC pipe. This pipe would then
connect to the hole in the ducting before the test section. Inside the test section
at the other end of the hole, the pipe would be secured by a PVC elbow. This
elbow would direct the mist toward the test section.

Figure 6.b.iv.a - View of PVC pipe and small fan installed on the lid of the
container housing the misting device.

In order for the mist to travel toward the test section, a second component
needed to be inserted in the lid of the container. This component was a computer
fan which would force the moisture into the tunnel. Problems were encountered
at this stage. The amount of mist was not enough to reach the test section after
the force of the fan was overcome.

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 Figure 6.b.iv.b - PVC pipe entry for misting system into the Wind Tunnel

Figure 6.b.iv.c - Inside view of hole location where PVC elbow was installed

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 This problem was tackled by placing the misting system in a smaller
container directly inside the tunnel. Results were immediately seen as a layer of
moisture was seen on the inner surfaces of the test section. However the water in
the misting system ran out before enough water settled on the test specimens
inside the test section. The water was refilled once and the problem was solved.
However this solution is not permanent and therefore for future consideration, a
pesticide spraying water nozzle will be installed through the hole originally
drilled for the misting system. This new misting system will have the force,
particle size and volume of water to generate the freezing conditions.

Figure 6.b.iv.d - View of misting system inside container. This container was
placed inside the tunnel.

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 v) Refrigeration System Concerns

The refrigeration selected for the cooling of the wind tunnel was same as
the one found in household air conditioning. The evaporator unit being used was
a 3.5 ton evaporator. The Problem encountered was with the refrigerant. The
Refrigerant being used was to be liquid nitrogen.

Figure 6.b.v.a - Liquid nitrogen tank connected to evaporator

The first concern with liquid nitrogen came when the boiling point was
taken into consideration. With the sudden change in phase, the fear was that a
potential explosion would occur. However after a couple of trial runs, the liquid
nitrogen was deemed safe. Since then two full runs of the system have been
completed with each lasting two hours on average. The refrigeration system ran
smoothly and the desired results were achieved.

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C. Testing
i) Wind Speed

The team recorded that the wind speed at the test section was 50 mph. The
wind speed was not reached up to what we calculated, which was around 120
mph. This happened because of too much head loss occurred in the tunnel.

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ii) Lowest Temperature Reached – Marcel

jkhugyg

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iii) Static Pressure – Marcel

jhuy

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iv) Ice Buildup

The Ultimate goal of the Icing Wind Tunnel was to achieve icing
conditions inside the test section. In order to test the capabilities of the wind
tunnel in forming ice, a stand was built for samples to be placed on. The stand
was a simple one made from a small piece of aluminum plate. The main portion
of the stand where the samples were to be housed was angled at 45o, with the
base parallel to the bottom of the test section. This angle would allow for
moisture to come in contact with the test samples.

Figure 6.c.iv.a - Test stand with 3 sample test specimens

Prior to running the wind tunnel, a hole was drilled in the bottom of the
test section. After drilling the hole, the fan and refrigeration system were
switched on. One the desired temperature was reached inside the test section, the
test stand was bolted and secured inside the test section.

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 Figure 6.c.iv.b - Test Stand being secured inside the test section

After leaving the test stand inside the test section for a few minutes, the
misting system is switched on. Within a few minutes of switching on the mist, ice
begins to form on the surface of the test specimens. This ensures that the Icing
Wind Tunnel has successfully completed its task.

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Figure 6.c.iv.c - View of Test stand inside test section with mist

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Figure 6.c.iv.d - Thin layers of ice formed on test specimens

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D. Safety Issue

Liquid Nitrogen - Marcel

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E. Cost Summary

No Items Price ( $ )
1 Fan 1000
2 Ducting
570
Insulation and PVC Jacket
3 Evaporator 800
4 Liquid Nitrogen 200
5 Test Section
Polycarbonate 120
Angles 50
Hinges 10
Screws 15

6 Misting system 250

Total 3015

The total of our cost is $3015.

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F. Future Considerations
i) Bigger Ducting

Figure 6.f.i.a – Contraction right after the test section

Figure 6.f.i.b – Contraction right after the fan

Instead of having the contraction part right after the fan, the team
recommended putting the contraction part before and after the test section.
Bigger ducting such as 24” diameter could be implanted. So the air has more time
to develop its flow and reaches the desired wind speed when it’s contracted
through the contraction part. After test section, the air will diffuse to bigger
volume and has longer time to be cooled down by the refrigerant.

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 ii) Longer Contraction

Figure 6.f.ii.a – 1.5 ft contraction Figure 6.f.ii.a – 3 ft contraction

The small contraction has the length of 14 ft. So by adding 1.5 ft length to
each contraction, the total length will be 17 ft. So, if space was not a restrain in
future design, the team recommended adding more length to the contraction
parts. Longer contraction will reduce static pressure drop and allow the air flow
to develop smoothly and reach the desired velocity at the test section.

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iii) Misting system - Marcel

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 iv) Fan

Fan for the IWT was chosen based on the fan’s actual CFM at the test
section. The team neglected the consideration that huge static pressure would
drop due to head loss. Therefore, the team experienced half of the wind speed
that the team expected.

For future consideration, the team suggested estimated head loss should
be calculated earlier before deciding which fan would be used for providing the
wind speed.

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G. Conclusion
This project taught the group many important facts about teamwork, hard
work, dedication, and pride. Throughout the senior design project, the group
grew and applied everything they have learned over the years at Stevens Institute
of Technology to accomplish the task set before them. Many nights of research,
calling manufacturers, and redesigning led to the successful building of their
project. By working together and pooling their knowledge, skills, and resources,
the group was able to build the IWT.

The team put all effort in order making this project a successful one. The
first six months were the hardest period where the team had lots of discussion
about what components to use and whether those components are suitable with
the calculations done in the previous phase.

Finally, the IWT was working perfectly fine with 50 mph of wind speed
and reached -12 F in about 45 minutes. The team also witnessed ice buildup on
the test specimen.

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Appendix: Pictures of IWT

Figure 7.a – The IWT without Fiberglass insulation installed

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Figure 7.b – The IWT right after insulation was installed

Figure 7.c – Different angle of IWT

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Figure 7.d – The IWT with Liquid Nitrogen tank

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Appendix: Design Implication

○ Ethical Issues – Not related

○ Environmental Impact - IWT might cause noise that will disturb the
harmony of people surround. Also, we are using the refrigerant
410, which will not hazard the environment.

○ Social Issues – Not related

○ Political Issues – Not related

○ Health and Safety Issues –We are not using any material or gas that
have the possibility giving harm to us or to other people.

○ Sustainability – Not related

○ Standardization/Standards – We tried to apply standardization in

our design, because it’s cheaper and easy to get. For an instance,
we used HVAC ducting because it’s the standard ducting for air
conditoned.

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Appendix: Nugget Chart – Phase I

63 | P a g e
 ME 423 Phase I Nugget Chart – Proposal & Conceptual Design

Title: Design and Development of an Icing Wind Tunnel

Team Members: Elie Fonrose, Ershaun Harris, Fatimah Naamat, Jeremy Nirmal, Marcel Ipince
Advisor: Prof. C. H. Choi Project #: 14 Date: October 2, 2008
 Project Objectives  Conceptual Designs and Highlights
- Develop a Small Scaled Icing Wind Tunnel - Closed loop wind tunnel
- - Refrigeration unit in order to generate low
temperatures
- Water nozzles to replicate forming of water
droplets on aircraft surface
 W hy This Project and State-of-the-ar t
- Replicates large scale wind tunnels used at
Drawing and Illustration of Promising Concepts
companies such as Boeing and Airbus
- Uses new technology – hydrophobic material
- Could prevent accidents due to icing in the
future
- May provide new insight on ice formation

 W hat Are the Key Areas/Aspects to Solve

- Heat Exchanger: Keep fluids from freezing
- Material Selection: Prevent thermal loss, Make
test section visible
- Corner Design: Reduce forces on joints and
optimize flow

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Appendix: Nugget Chart – Phase II

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 ME 423 Phase II Nugget Chart – Design Selection and Technical Analysis

Title: Design and Development of an Icing Wind Tunnel

Team Members: Fatimah Naamat, Jeremy Nirmal, Elie Fonrose, Ershaun Harris, Marcel Ipince
Advisor: Prof. C. H. Choi Project #: 14 Date:11/12/08

 Project Objectives  Results Obtained at This Point

Design and develop a small scaled Icing Wind Tunnel Vapor Compression System – Qin = 3.687 ton
Contraction Ratio – 8 : 1
CFM of the fan – 15100 = 257 mph
 Types and Focuses of Technical Analysis Thermal Resistant – 4.98 (oF/(Btu/hr))
Water Nozzle – Q = 0.0476 GPM = 72 Psi
Refrigeration System – Vapor Compression System
- Heat Exchanger Calculation
Drawing and Illustration (about technical analysis performed)
( LMTD and NTU)
Bernoulli’s Principle - Contraction Ratio
Fan Selection - CFM of the blade
Ducting and Insulation - Heat Transfer Calculation Test Section

Water Nozzle – Humidity Ratio Water

Spray

 Design Specifications
De-icing
mechanism
Length = 9.8 ft
Height = 5.4 ft
Width = 2.67 ft
Wind speed = 257 mph Fan
Turning Evaporator
Vane

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Appendix: Nugget Chart – Phase III

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Appendix: Nugget Chart – Phase IV

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Appendix: Nugget Chart – Phase V

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Appendix: Nugget Chart – Phase VI

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I

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Appendix: Gantt Chart

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Appendix: List of References

a) Article/Journal :

i). Goodrich, De-icing and Specialty Systems, Uniontown, Ohio,

“Technical Description of Goodrich DSS Icing Wind Tunnel”,
Feb 6th, 2002.

ii). C. Scott Bartlett, “Icing Test Capabilities in the Aero-

propulsion System Test Facility at the Arnold Engineering
Development Center”, June 20-23, 1994

iii). Andrea G. Kraj and Eric L. Bibeau, “Icing Characteristics

and Mitigation Strategies for Wind Turbines in Cold Climates”

b). Textbook:

i). Frank White, “Fluid Mechanics”, 6th edition

ii). Yunus A Cengel, “ Heat and Mass Transfer”, 3rd edition

iii). Michael J. Moran and Howard N. Shapiro, “ Fundamentals

of Engineering Thermodynamics”, 6th edition

c). Website:

i). Cox and Company, http://www.coxandco.com/

ii). Mc Master Carr, http://www.mcmaster.com/

iii). Engineering Tool Box,

http://www.engineeringtoolbox.com/

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