Mar

23

Turbocharger development with Simcenter FLOEFD

Executive summary

Borusan R&D is responsible for developing research and development (R&D) strategies and conducting R&D studies for the entire Borusan Group, which comprises the steel, logistics, energy, automotive and distributorship divisions. The automotive division, Supsan, produces engine components for the original equipment manufacturer (OEM) and after-sales market.

Supsan is the largest manufacturer of engine valves in Turkey and distributes turbochargers, among other products. Supsan and Borusan R&D started a collaborative project with the goal of developing and manufacturing completely new turbochargers. This paper describes how Simcenter™ FLOEFD™ was used in the new turbocharger project.

Mert Alpaya
Researcher
Borusan R&D

Turbocharger background

The turbocharger is a small, complex and critical component of the vehicle because it directly determines the engine performance.
A turbocharger consists of two different types of turbomachines, a turbine and a compressor, which are combined in one single component. Multiple design studies must be carried out for the design: an analysis of the flow conditions and heat distribution, as well as bearing design and lubrication. The high temperature of the exhaust gases makes the design critical.

The exhaust gas from the engine drives the impeller on the exhaust side, and with the common shaft the impeller at the cold air side is driven, which then sucks in and compresses the air on the air intake side. The compressed air increases the combustion efficiency in the engine.

The turbocharger developed in this project is shown in figure 1. It is designed for 1.5-litre engines in series vehicles. The rotational speed is controlled by a waste gate actuator.

The turbocharger was tested on a test rig (figure 2). The turbine inlet pressure has been changed to modify the rotational speed. The flow rate and the pressure were measured. Twelve different test cases were measured on the test rig and later compared with the simulation results.

Figure 2: Test rig.

The CAD model for the compressor side is shown in figure 3. A fictional body was used to define the rotating area; the boundary conditions were mass flow at the inlet and total pressure at the outlet.

For the turbine side, two different cases were investigated in which the wastegate lid was opened and closed, for different rotational speeds (figure 4). A total inlet pressure and an environmental pressure for the outlet were applied. Continue reading 

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