SolidWorks Design of Vortex Core & Housing

Vortex Core & Housing – SolidWorks Design Brief (Rev C) Scope: Mechanical design only. This brief defines the vortex core, swirler inserts, outlet jets, and housing with thrust/exhaust features for CAD in SolidWorks. 1. Core Geometry - Form: Triple-channel spiral (inner, middle, outer). - Overall envelope: Ø100 mm × 100 mm tall. - Central bore: 30 mm ID (shaft passage). - Material: 6061-T6 aluminum (machined or SLM). - Estimated mass: 0.6–0.9 kg (non-binding). 2. Channel Specifications - Inner channel width: 6–7 mm (largest). - Middle channel width: 5–6 mm. - Outer channel width: 5–6 mm. - Channel height: 100 mm (full core height). - Surface finish: Ra ≤ 1.6 µm on channel walls. 3. Inlet Swirler Inserts - Location: Top of each channel - Geometry: 3 fixed blades at 30° to axial flow. - Blade thickness: 1.4–1.6 mm; straight plate (no camber). - Chord length: 18–25% of local circumference. - Tip clearance: 0.3–0.5 mm to channel wall. - Mounting: Bayonet-style keyed pocket; swappable inserts. - Variants by handedness: Right-hand (CW) and Left-hand (CCW). - Orientation (viewed from inlet/top): Inner = Right-hand (CW), Middle = Left-hand (CCW), Outer = Right-hand (CW). 4. Outlet Jets - Location: Bottom of each channel. - Jet axis: 30° relative to axial direction (fixed). - Jet diameters: Inner ~3.0 mm; Middle ~2.5 mm; Outer ~2.5 mm. - Evenly spaced at each channel exit . 5. Core Housing - Type: housing enclosing the core with 3–4 mm radial clearance. - Material: 6061-T6 aluminum alloy or composite. - Top: Flanged mounting ring; provision for swirler pocket access. - Exhaust ports: Two tubes (ID 10–12 mm) exiting radially from housing. 5.1 Internal Thrust Face & Exhaust Manifold - Provide an internal annular thrust face for the core to rotate against and to collect exhaust air. - Geometry: Annular ring (width 4–6 mm) machined into the housing inner base. - Surface: Low-friction wear surface (hard anodized Al or PTFE/PEEK wear plate insert, 0.8–1.2 mm thick). - Function: Acts as a thrust running surface while allowing air to exit through manifold passages. - Exhaust manifold: Slot passages (2–4 slots, each 3–4 mm wide × 10–14 mm long) lead from the region above the thrust face into the two exhaust tubes. - Gap to core: Maintain 0.20–0.30 mm nominal axial running clearance above the thrust face when assembled (before ball contact). 5.2 Jet Landing Face / 30° Deflector - Provide a 30° inclined landing face directly downstream of each outlet jet in the housing base region. - Geometry: Circular conical or faceted ramp at 30°; local ramp width 2–3 mm; positioned to intersect the jet axes. - Purpose: To direct jet flow tangentially and assist in maintaining the designed flow path. - Ensure the deflector does not obstruct manifold slots; maintain at least 1.5 mm clearance from slot edges. 6. Bottom Bearing – Ballpoint Style - Ball element: Ø2.0–3.0 mm hardened steel or ceramic ball retained in a cup in the housing base. - Core interface: 60° included-angle conical recess at the core/shaft bottom for point contact. - Optional axial preload spring acting on the ball seat (light preload 2–5 N). - Concentricity of ball seat to bore: ≤ 0.02 mm. 7. Tolerances & Fits - Swirler pocket fit: H7/g6; radial clearance 0.02–0.05 mm. - Channel width tolerance: ±0.05 mm (each channel). - Jet diameter tolerance: ±0.05 mm. - Housing-to-core radial clearance: 3–4 mm nominal; minimum 2.5 mm at worst-case tolerance stack. - Axial running clearance above thrust face: 0.20–0.30 mm (see Section 5.1). - Surface finish: Ra ≤ 1.6 µm (channels and thrust face); Ra ≤ 0.8 µm recommended on deflector ramp. 8. Deliverables - SolidWorks Parts: Core, Housing, Swirler Inserts (RH/LH), Ball Bearing Seat components. - SolidWorks Assembly with mates and defined clearances. - STEP files for all parts and assembly. - 2D drawings with full dimensions, tolerances, and GD&T callouts where applicable.

Project ID: 39720821