NUMERICAL STUDY OF ALUMINUM BLADE OF AN AXIAL FAN WITH VARIOUS TWIST ANGLE AND CHORD LENGTH USING ABAQUS SOFTWARE.
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NUMERICAL STUDY OF ALUMINUM BLADE OF AN AXIAL
FAN WITH VARIOUS TWIST ANGLE AND CHORD
LENGTH USING ABAQUS SOFTWARE
Thesis
Organized to meet a part of the requirements to achieve the master degree of
Mechanical Engineering
By
EBRAHIM MUSTAFA ABDALLA
S951302504
DEPARTMENT OF MECHANICAL ENGINEERING
ENGINEERING FACULTY
SEBELAS MARET UNIVERSITY
SURAKARTA
2015
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ORIGINALITY AND PUBLICATION STATEMENT
We declared that:
1.
Thesis entitled: NUMERICAL STUDY OF ALUMINUM BLADE OF AN
AXIAL FAN WITH VARIOUS TWIST ANGLE AND CHORD LENGTH
there
USING ABAQUS SOFTWARE
is no scientific papers that have been asked by others to obtain academic degrees
and there is no work or opinion ever written or published by another person
except in writing used as a reference in this text and a reference source as well as
mentioned in the bibliography. If at a later proved there is plagiarism in scientific
papers, then I am willing to accept sanctions in accordance with the provisions of
the legislation (Permendiknas No 17, tahun 2010)
2.
Publication of some or all of the contents of the Thesis or other scientific forums
and permission must include the author and the team as a supervisor. If within at
least one semester (six months after examination of the thesis) I did not make the
publication of part or entire of this thesis, the Program in Mechanical
Engineering of UNS has the right to publish in a scientific journal published by
Study Program in Mechanical Engineering of UNS. If I violate of the provisions
of this publication, then I am willing to get an academic sanction.
Surakarta, June 2015
Student,
EBRAHIM MUSTAFA ABDALLA
S951302504
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MOTTO
will never know the real answer, before you
(anonim)
you want the respect of others, you must respect yourself
(anonim)
"Be a good man, because Allah loves the goodness"
(The writer)
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DEDICATION
This paper is dedicated to:
1. Mustafa and Hansa, my parents who have been educated with simplicity,
compassion with tolerance and patience above all prayer and boundless
sacrifices that he always gave to the author.
2. Rabiah and Hasna and Fatima and Yusuf my wife and my children dear, who
always gives warmth and motivation that makes its own spirit to the author.
3. Brother and sister who always gives a special motivation so I have always
been motivated to move forward.
commit to user
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ACKNOWLEDGEMENT
All praise and gratitude writer prayed Almighty God's gift. Because thanks to
NUMERICAL STUDY OF
ALUMINUM BLADE OF AN AXIAL FAN WITH VARIOUS TWIST ANGLE
AND CHORD LENGTH USING ABAQUS SOFTWARE . The authors wish to
thank you especially to the supervisor that the Honorable. Dr. Danardono DPT and
Dr.Triyono ST. Which has deigned to provide motivation, direction, guidance,
knowledge, inputs and corrections to this thesis can be resolved. As well as to the
entire to fathers Mechanical Engineering
lecturer Engineering Faculty Program
Sebelas Maret University of Surakarta who has given science and knowledge to the
author for his education at the Graduate Program, Sebelas Maret University of
Surakarta.
On this occasion, the authors also express gratitude to:
1. Prof. Dr. Ravik Karsidi, M.S., as Rector of the University of Sebelas Maret,
which has given permission to the author and the opportunity to participate in and
complete the Graduate Program at the Sebelas Maret University of Surakarta.
2. Prof. Dr. M. Furqon Hidayatullah, M.Pd., as Director of the Graduate Program,
Sebelas Maret University of Surakarta who has given the author the opportunity
to gain knowledge of education in the Graduate Program.
3. Dr. Danardono , as the first supervisor who has given direction and guidance in
the preparation of the thesis.
4. Dr. Triyono, ST.,MT. as the Second supervisor who has given direction and
guidance in the preparation of the thesis
5. Dr. Triyono, ST.,MT. as Head of Mechanical Engineering Graduate Program,
University of Maret , who has given direction and guidance in the preparation of
the thesis
6. All those who helped in completing this thesis and the author cannot describe one
by one.
Care and support they have given to the author will be given just reward by
Allah Almighty and be charitable and glory for all of us.
Ebrahim Mustafa Abdalla
S951302504
commit to user
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perpustakaan.uns.ac.id
Ebrahim
Mustafa
digilib.uns.ac.id
Abdalla,
S951302504
(NUMERICAL
STUDY
OF
ALUMINUM BLADE OF AN AXIAL FAN WITH VARIOUS TWIST
ANGLES AND CHORD LENGTHS USING ABAQUS SOFTWARE). Thesis:
The Graduate Program in Mechanical EngineeringProgram, Sebelas Maret
University, Surakarta, 2015. Supervisor I: D.Danardono D.P.T., S.T., M.T., Ph.D.
Supervisor II: Dr. Triyono, ST., MT.
ABSTRACT
The purpose of this work is to optimize the blade design of an axial-flow fan.
Four different chord length and five twisting angle of their blades were studied. The
fan was designed by using NACA 5505 series. The first investigation is conducted to
the blade design in the variation of chord length. The base chord length is constant of
130 mm and the tip is vary from 84, 92, 102 and 110 mm. The second study is in the
variation of twisting angle from 0, 10, 20, 30 and 40o. The performances of the fans
were measured in a Von Mises stress criterion under pressure of 500 Pa. From the
variation of chord length, the shortest length of 84 mm was delivered the lowest
stress. While the variation of twisting angle, the lowest stress is delivered by 40o of
twisting angle. The proposed blade design is presented by using combination of
twisting angle 10, 20, 30 and 40o in single blade model. The blade total length of
446.5 mm is divided into four parts and every part have different twisting angle.
From the stress result, the proposed model was delivered lower stress compared to the
other models.
Keywords: Axial fan, twist angle, chord length, stress analysis, finite element
method.
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CONTENT LIST
TITLE PAGE ........................................................................................................
i
APPROVAL PAGE ..............................................................................................
ii
SUPERVISOR ENDORSEMENT .......................................................................
iii
STATEMENT OF ORIGINALITY AND PUBLICATION OF CONTENTS
THESIS .................................................................................................................
iv
MOTTO ................................................................................................................
v
DEDICATION ......................................................................................................
vi
INTRODUCTION ................................................................................................
vii
ABSTRACT ..........................................................................................................
viii
CONTENT LIST ...................................................................................................
ix
FIGURE LIST .......................................................................................................
xi
TABLE LIST ........................................................................................................
xiii
CHAPTER I
CHAPTER II
INTRODUCTION ....................................................................
1
1.1 Background ........................................................................
1
1.2 Problem statement ..............................................................
2
1.3 Thesis objective and benefit ...............................................
2
1.4 Thesis Limitation ................................................................
2
LITERATURE REVIEW ........................................................
3
2.1 Study Literature .................................................................
3
2.1.1
Axial Flow Fan Construction and Efficiency ......
3
2.1.2
NACA series airfoils ..........................................
4
2.1.3
Finite Element Analysis Method .........................
5
2.1.4
Chord length, and twist angle optimization .........
6
2.1.5
Axial Flow Fans ..................................................
8
2.1.6
Airfoil ..................................................................
10
2.1.7
Air velocity type ..................................................
11
2.1.8
Blade angle and twist...........................................
11
2.1.9
Analysis Method and Software ...........................
12
2.2 Basic Theory ......................................................................
13
2.2.1
Abaqus and Modeling..........................................
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CHAPTER III
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2.2.2
Von Miss Stress ...................................................
14
2.2.3
Equation ...............................................................
14
METHODOLGY .....................................................................
16
3.1 Fan properties ....................................................................
16
3.2 Blade properties and Material ............................................
16
3.3 Airfoil Generator Design ...................................................
17
3.4 ABAQUS stress Analysis ..................................................
17
3.5 Section of Airfoil with AutoCAD .....................................
18
3.6 CATIA to Design a Blade with Different Twist Angle
and thickness .....................................................................
19
3.7 Blade Analysis with ABAQUS .........................................
20
3.8 Mesh Convergence Study ..................................................
21
3.9 Twist Angle .......................................................................
22
3.10 The Proposed Model .........................................................
23
3.11 Flow Chart of the Research Methodology ........................
24
RESULTS AND DISCUSSION ...............................................
25
4.1 Validation of Analysis ........................................................
25
4.2 Influence of Chord Length ..................................................
26
4.3 Influence of Twisting Angle ...............................................
28
4.4 Results of Proposed Model .................................................
32
CONCLUSION AND SUGGESTION .....................................
36
5.1 Conclusion ..........................................................................
36
5.2 Suggestion...........................................................................
36
REFERENCE .......................................................................................................
37
APPENDIX ...........................................................................................................
40
CHAPTER IV
CHAPTER V
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FIGURE LIST
Figure 2.1
NACA5505 Airfoil ..........................................................................
5
Figure 2.2
Fan performance curve ....................................................................
9
Figure 2.3
Airfoil shape of cross section...........................................................
10
Figure 2.4 Two views of a fabricated tube axial fan wheel, with larger blade
angles at hub and smaller blade angles at the tip .............................
12
Figure 3.1
Axial Aluminum .............................................................................
16
Figure 3.2
NACA 5505 Airfoil in AutoCAD ....................................................
18
Figure 3.3
Designed blade without twist angle .................................................
19
Figure 3.4
Designed blade with 20° of twist angle ...........................................
19
Figure 3.5
The first module in ABAQUS: module part ....................................
20
Figure 3.6
Assign section material to the blade ................................................
20
Figure 3.7
Loading and boundary condition .....................................................
21
Figure 3.8
Meshed blade ...................................................................................
21
Figure 3.9
Mesh dimensional rectangular flat elements ...................................
22
Figure 3.10 Airfoil shape of cross section with different twist angles ................
22
Figure 3.11 Twist angle in root and tip ...............................................................
22
Figure 3.12 The proposed model use different twisting angle in four span ........
23
Figure 3.13 Flow Chart of the Research Methodology .......................................
24
Figure 4.1
Stress distribution of NACA 5514 under load pressure 0.5 MPa. ...
25
Figure 4.2
Results validation .............................................................................
26
Figure 4.3
Influenced of tip chord length in the stress generation ...................
27
Figure 4.4
Stress distribution of NACA 5505, tip chord length 110 mm .........
27
Figure 4.5
Stress distribution of NACA 5505, tip chord length 84 mm ...........
28
Figure 4.6
Influenced of twisting angle in stress generation for tip chord
length 84 mm ...................................................................................
Figure 4.7
Influenced of twisting angle in stress generation for tip chord
length 92 mm ...................................................................................
Figure 4.8
30
Influenced of twisting angle in stress generation for tip chord
length 102 mm ................................................................................
Figure 4.9
29
30
Influenced of twisting angle in stress generation for tip chord
length 110 mm .................................................................................
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Figure 4.10 Influenced of twisting angle in stress generation for all tip chord
length ...............................................................................................
31
Figure 4.11 Maximum stress of proposed model in variation of tip chord
length ...............................................................................................
33
Figure 4.12 Stress distribution of proposed model of NACA 5505, tip of
chord length 84 mm .........................................................................
33
Figure 4.13 Stress distribution of proposed model of NACA 5505, tip of
chord length 110 mm .......................................................................
34
o
Figure 4.14 Maximum stress comparison between proposed model, 40
twisting angle and 0o twisting angle ................................................
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TABLE LIST
Table 3.1
Aluminum 6061-T91 properties ......................................................
Table 3.2
Some exported points from NACA 5 Digits Series Profile
Generator for NACA 5505 ..............................................................
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NUMERICAL STUDY OF ALUMINUM BLADE OF AN AXIAL
FAN WITH VARIOUS TWIST ANGLE AND CHORD
LENGTH USING ABAQUS SOFTWARE
Thesis
Organized to meet a part of the requirements to achieve the master degree of
Mechanical Engineering
By
EBRAHIM MUSTAFA ABDALLA
S951302504
DEPARTMENT OF MECHANICAL ENGINEERING
ENGINEERING FACULTY
SEBELAS MARET UNIVERSITY
SURAKARTA
2015
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ORIGINALITY AND PUBLICATION STATEMENT
We declared that:
1.
Thesis entitled: NUMERICAL STUDY OF ALUMINUM BLADE OF AN
AXIAL FAN WITH VARIOUS TWIST ANGLE AND CHORD LENGTH
there
USING ABAQUS SOFTWARE
is no scientific papers that have been asked by others to obtain academic degrees
and there is no work or opinion ever written or published by another person
except in writing used as a reference in this text and a reference source as well as
mentioned in the bibliography. If at a later proved there is plagiarism in scientific
papers, then I am willing to accept sanctions in accordance with the provisions of
the legislation (Permendiknas No 17, tahun 2010)
2.
Publication of some or all of the contents of the Thesis or other scientific forums
and permission must include the author and the team as a supervisor. If within at
least one semester (six months after examination of the thesis) I did not make the
publication of part or entire of this thesis, the Program in Mechanical
Engineering of UNS has the right to publish in a scientific journal published by
Study Program in Mechanical Engineering of UNS. If I violate of the provisions
of this publication, then I am willing to get an academic sanction.
Surakarta, June 2015
Student,
EBRAHIM MUSTAFA ABDALLA
S951302504
commit to user
perpustakaan.uns.ac.id
digilib.uns.ac.id
MOTTO
will never know the real answer, before you
(anonim)
you want the respect of others, you must respect yourself
(anonim)
"Be a good man, because Allah loves the goodness"
(The writer)
commit to user
v
perpustakaan.uns.ac.id
digilib.uns.ac.id
DEDICATION
This paper is dedicated to:
1. Mustafa and Hansa, my parents who have been educated with simplicity,
compassion with tolerance and patience above all prayer and boundless
sacrifices that he always gave to the author.
2. Rabiah and Hasna and Fatima and Yusuf my wife and my children dear, who
always gives warmth and motivation that makes its own spirit to the author.
3. Brother and sister who always gives a special motivation so I have always
been motivated to move forward.
commit to user
vi
perpustakaan.uns.ac.id
digilib.uns.ac.id
ACKNOWLEDGEMENT
All praise and gratitude writer prayed Almighty God's gift. Because thanks to
NUMERICAL STUDY OF
ALUMINUM BLADE OF AN AXIAL FAN WITH VARIOUS TWIST ANGLE
AND CHORD LENGTH USING ABAQUS SOFTWARE . The authors wish to
thank you especially to the supervisor that the Honorable. Dr. Danardono DPT and
Dr.Triyono ST. Which has deigned to provide motivation, direction, guidance,
knowledge, inputs and corrections to this thesis can be resolved. As well as to the
entire to fathers Mechanical Engineering
lecturer Engineering Faculty Program
Sebelas Maret University of Surakarta who has given science and knowledge to the
author for his education at the Graduate Program, Sebelas Maret University of
Surakarta.
On this occasion, the authors also express gratitude to:
1. Prof. Dr. Ravik Karsidi, M.S., as Rector of the University of Sebelas Maret,
which has given permission to the author and the opportunity to participate in and
complete the Graduate Program at the Sebelas Maret University of Surakarta.
2. Prof. Dr. M. Furqon Hidayatullah, M.Pd., as Director of the Graduate Program,
Sebelas Maret University of Surakarta who has given the author the opportunity
to gain knowledge of education in the Graduate Program.
3. Dr. Danardono , as the first supervisor who has given direction and guidance in
the preparation of the thesis.
4. Dr. Triyono, ST.,MT. as the Second supervisor who has given direction and
guidance in the preparation of the thesis
5. Dr. Triyono, ST.,MT. as Head of Mechanical Engineering Graduate Program,
University of Maret , who has given direction and guidance in the preparation of
the thesis
6. All those who helped in completing this thesis and the author cannot describe one
by one.
Care and support they have given to the author will be given just reward by
Allah Almighty and be charitable and glory for all of us.
Ebrahim Mustafa Abdalla
S951302504
commit to user
vii
perpustakaan.uns.ac.id
Ebrahim
Mustafa
digilib.uns.ac.id
Abdalla,
S951302504
(NUMERICAL
STUDY
OF
ALUMINUM BLADE OF AN AXIAL FAN WITH VARIOUS TWIST
ANGLES AND CHORD LENGTHS USING ABAQUS SOFTWARE). Thesis:
The Graduate Program in Mechanical EngineeringProgram, Sebelas Maret
University, Surakarta, 2015. Supervisor I: D.Danardono D.P.T., S.T., M.T., Ph.D.
Supervisor II: Dr. Triyono, ST., MT.
ABSTRACT
The purpose of this work is to optimize the blade design of an axial-flow fan.
Four different chord length and five twisting angle of their blades were studied. The
fan was designed by using NACA 5505 series. The first investigation is conducted to
the blade design in the variation of chord length. The base chord length is constant of
130 mm and the tip is vary from 84, 92, 102 and 110 mm. The second study is in the
variation of twisting angle from 0, 10, 20, 30 and 40o. The performances of the fans
were measured in a Von Mises stress criterion under pressure of 500 Pa. From the
variation of chord length, the shortest length of 84 mm was delivered the lowest
stress. While the variation of twisting angle, the lowest stress is delivered by 40o of
twisting angle. The proposed blade design is presented by using combination of
twisting angle 10, 20, 30 and 40o in single blade model. The blade total length of
446.5 mm is divided into four parts and every part have different twisting angle.
From the stress result, the proposed model was delivered lower stress compared to the
other models.
Keywords: Axial fan, twist angle, chord length, stress analysis, finite element
method.
commit to user
viii
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CONTENT LIST
TITLE PAGE ........................................................................................................
i
APPROVAL PAGE ..............................................................................................
ii
SUPERVISOR ENDORSEMENT .......................................................................
iii
STATEMENT OF ORIGINALITY AND PUBLICATION OF CONTENTS
THESIS .................................................................................................................
iv
MOTTO ................................................................................................................
v
DEDICATION ......................................................................................................
vi
INTRODUCTION ................................................................................................
vii
ABSTRACT ..........................................................................................................
viii
CONTENT LIST ...................................................................................................
ix
FIGURE LIST .......................................................................................................
xi
TABLE LIST ........................................................................................................
xiii
CHAPTER I
CHAPTER II
INTRODUCTION ....................................................................
1
1.1 Background ........................................................................
1
1.2 Problem statement ..............................................................
2
1.3 Thesis objective and benefit ...............................................
2
1.4 Thesis Limitation ................................................................
2
LITERATURE REVIEW ........................................................
3
2.1 Study Literature .................................................................
3
2.1.1
Axial Flow Fan Construction and Efficiency ......
3
2.1.2
NACA series airfoils ..........................................
4
2.1.3
Finite Element Analysis Method .........................
5
2.1.4
Chord length, and twist angle optimization .........
6
2.1.5
Axial Flow Fans ..................................................
8
2.1.6
Airfoil ..................................................................
10
2.1.7
Air velocity type ..................................................
11
2.1.8
Blade angle and twist...........................................
11
2.1.9
Analysis Method and Software ...........................
12
2.2 Basic Theory ......................................................................
13
2.2.1
Abaqus and Modeling..........................................
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CHAPTER III
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2.2.2
Von Miss Stress ...................................................
14
2.2.3
Equation ...............................................................
14
METHODOLGY .....................................................................
16
3.1 Fan properties ....................................................................
16
3.2 Blade properties and Material ............................................
16
3.3 Airfoil Generator Design ...................................................
17
3.4 ABAQUS stress Analysis ..................................................
17
3.5 Section of Airfoil with AutoCAD .....................................
18
3.6 CATIA to Design a Blade with Different Twist Angle
and thickness .....................................................................
19
3.7 Blade Analysis with ABAQUS .........................................
20
3.8 Mesh Convergence Study ..................................................
21
3.9 Twist Angle .......................................................................
22
3.10 The Proposed Model .........................................................
23
3.11 Flow Chart of the Research Methodology ........................
24
RESULTS AND DISCUSSION ...............................................
25
4.1 Validation of Analysis ........................................................
25
4.2 Influence of Chord Length ..................................................
26
4.3 Influence of Twisting Angle ...............................................
28
4.4 Results of Proposed Model .................................................
32
CONCLUSION AND SUGGESTION .....................................
36
5.1 Conclusion ..........................................................................
36
5.2 Suggestion...........................................................................
36
REFERENCE .......................................................................................................
37
APPENDIX ...........................................................................................................
40
CHAPTER IV
CHAPTER V
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FIGURE LIST
Figure 2.1
NACA5505 Airfoil ..........................................................................
5
Figure 2.2
Fan performance curve ....................................................................
9
Figure 2.3
Airfoil shape of cross section...........................................................
10
Figure 2.4 Two views of a fabricated tube axial fan wheel, with larger blade
angles at hub and smaller blade angles at the tip .............................
12
Figure 3.1
Axial Aluminum .............................................................................
16
Figure 3.2
NACA 5505 Airfoil in AutoCAD ....................................................
18
Figure 3.3
Designed blade without twist angle .................................................
19
Figure 3.4
Designed blade with 20° of twist angle ...........................................
19
Figure 3.5
The first module in ABAQUS: module part ....................................
20
Figure 3.6
Assign section material to the blade ................................................
20
Figure 3.7
Loading and boundary condition .....................................................
21
Figure 3.8
Meshed blade ...................................................................................
21
Figure 3.9
Mesh dimensional rectangular flat elements ...................................
22
Figure 3.10 Airfoil shape of cross section with different twist angles ................
22
Figure 3.11 Twist angle in root and tip ...............................................................
22
Figure 3.12 The proposed model use different twisting angle in four span ........
23
Figure 3.13 Flow Chart of the Research Methodology .......................................
24
Figure 4.1
Stress distribution of NACA 5514 under load pressure 0.5 MPa. ...
25
Figure 4.2
Results validation .............................................................................
26
Figure 4.3
Influenced of tip chord length in the stress generation ...................
27
Figure 4.4
Stress distribution of NACA 5505, tip chord length 110 mm .........
27
Figure 4.5
Stress distribution of NACA 5505, tip chord length 84 mm ...........
28
Figure 4.6
Influenced of twisting angle in stress generation for tip chord
length 84 mm ...................................................................................
Figure 4.7
Influenced of twisting angle in stress generation for tip chord
length 92 mm ...................................................................................
Figure 4.8
30
Influenced of twisting angle in stress generation for tip chord
length 102 mm ................................................................................
Figure 4.9
29
30
Influenced of twisting angle in stress generation for tip chord
length 110 mm .................................................................................
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Figure 4.10 Influenced of twisting angle in stress generation for all tip chord
length ...............................................................................................
31
Figure 4.11 Maximum stress of proposed model in variation of tip chord
length ...............................................................................................
33
Figure 4.12 Stress distribution of proposed model of NACA 5505, tip of
chord length 84 mm .........................................................................
33
Figure 4.13 Stress distribution of proposed model of NACA 5505, tip of
chord length 110 mm .......................................................................
34
o
Figure 4.14 Maximum stress comparison between proposed model, 40
twisting angle and 0o twisting angle ................................................
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TABLE LIST
Table 3.1
Aluminum 6061-T91 properties ......................................................
Table 3.2
Some exported points from NACA 5 Digits Series Profile
Generator for NACA 5505 ..............................................................
commit to user
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17
18