Research Paper

Volume : 3 | Issue : 5 | May 2014 ISSN No 2277 - 8179

Computational Fluid Dynamics Analysis of

A Turbocharger System
Shalini Bhardwaj
Yashwant Buke

ABSTRACT

Engineering

KEYWORDS : CFD, Turbocharger, Compressor, Turbine

Assistant Professor, Department of Mechanical, IES, IPS ACADEMY, INDORE (M.P.)

Assistant Professor, Department of Mechanical, IES, IPS ACADEMY, INDORE (M.P.)

In recent years, manufacturing industries are employed a new manufacturing methods to increase environmental protection and improved output. CFD is a complimentaryexperimental, theoreticalapproach forsimulating real flow as it is much cheaper than experimental testing.CFDas an analyzing tool for the turbocharger design, enhances off-design operation and improves performance. This paper describes the procedure of analyzing the turbocharger flow passage using CFD.

I. INTRODUCTION
Turbocharger is a method of forced induction. Forced induction
is the process of cramming more air into an internal combustion engines for more horsepower that is normally draws by its
own vacuums, so that the cylinders contains denser air , which
results in a bigger explosion, thus more horsepower. This paper
describes the procedure of simulating fluid flow in turbochargers turbines and compressors with the help of CFD. Computational Fluid Dynamics (CFD) is a cost affected tool to provide
detailed flow information inside the complete turbocharger. In
present work, numerical flow simulation in turbocharger (turbine and compressor) has been carried out using commercial
code ANSYS CFX. The investigated turbocharger was composed
by centrifugal compressor and radial- axial turbine with diffuser, casing, blades, impellers and return channel. CFD results
were validated with experimental results for certain chosen
performance parameters such as pressure ratio, vector plots
and polytrophic efficiencies. The variation of efficiency and discharge with speed factor are presented in graphical form. The
pressure and velocity distribution at runner blade for both compressor and turbine are also presented.
II. GEOMETRY
1. Turbocharger
Turbocharger is extensively used throughout the automobile
industries as they can enhance the output of an internal combustion engine without the need to increase its cylinder capacity. A turbocharger is a device that adds to the engine in order
to increase power and efficiency. Some like to say that a turbocharger is a centrifugal supercharger driven by exhaust gas instead of mechanically, the only differences are the way of the
system is powered.

Compressor
Turbocharger compressors are generally centrifugal compressors consisting of three essential components: compressor
wheel, diffuser, and housing. With the rotational speed of the
wheel, air is drawn in axially, accelerated to high velocity and
then expelled in a radial direction.
Compressor Wheel (Impeller)
Compressor impellers are produced using a variant of the aluminum investment casting process.

Fig2 - Compressor wheel (impeller)

Compressor Cover
Compressor housings are also made in cast aluminum.

Fig3- Compressor cover

Figure1. Turbocharger cross section

Turbocharger components are classified as turbine housing (volute), turbine (radial and axial flow type), compressor, compressor wheel (impeller), diffuser, bearing system ,bearing housing
, control system ,waste gates, inter cooler. Turbocharger having
a single shaft on which both compressor and turbine is takes
place. Back plate (support the compressor housing, provides
aero surface, Center housing (supports the rotating group).

Turbine
The turbocharger turbine, which consists of a turbine wheel
and turbine housing, converts the engine exhaust gas into mechanical energy to drive the compressor. The gas, which is restricted by the turbines flow cross-sectional area, results in a
pressure and temperature drop between the inlet and outlet.
This pressure drop is converted by the turbine into kinetic energy to drive the turbine wheel.
There are two main turbine types: axial and radial flow. In the
axial-flow type, flow through the wheel is only in the axial direction. In radial-flow turbines, gas inflow is centripetal, i.e. in a
radial direction from the outside in, and gas outflow in an axial
direction.

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Up to a wheel diameter of about 160 mm, only radial-flow turbines are used. This corresponds to an engine power of approximately 1000 kW per turbocharger. From 300 mm onwards, only
axial-flow turbines are used. Between these two values, both
variants are possible.
Wheel
The Turbine Wheel is housed in the turbine casing and is connected to a shaft that in turn rotates the compressor wheel.

Fig4 Turbine wheel

Turbine Housing
Turbine housings are manufactured in various grades of spheroid graphite iron to deal with thermal fatigue and wheel burst
containment.

Fig5-: Turbine housing

Bearing Housing
A grey cast iron bearing housing provides locations for a fully
floating bearing system for the shaft, turbine and compressor
which can rotate at speeds up to 170,000 rev/min. Shell molding is used to provide positional accuracy of critical features of
the housing such as the shaft bearing and seal locations.

Research Paper
various mass-flow rates. For designers, prediction of operating
characteristics curve is most important. All theoretical methods
for prediction of efficiency merely give a value; but one is unable
to determine the root cause for the poor performance. Due to
the development of CFD code, one can get the efficiency value as
well as observe actual intensive, reducing time and, hence, cost.
Advanced solvers contain algorithms which enable robust solutions of the flow field in a reasonable time. As a result of these
factors, Computational Fluid Dynamics is now an established
industrial design tool, helping to reduce design time scales and
improve processes throughout the engineering world. CFD provides a cost-effective and accurate alternative to scale model
testing with variations on the simulation being performed
quickly offering obvious advantages; The CFD occupies today a
very significant place in the disciplines of fluid mechanics and
turbo machinery due to the great progress in the development
of numerical methods and computing power. However, the initially use of CFD tools to design a new machine represents a non
realistic procedure (Arnone, 1999). The design of a new machine (or upgrading an existing machine) would require a great
investment of time without guarantee of success. Along with the
introduction of CFD tools, the incorporation of computer aided
design (CAD) codes has speeded up the design process because
of a faster geometry and grid generation.
Recent advances in computing power, together with powerful
graphics and interactive 3D manipulation of models have made
the process of creating a CFD model and analyzing results much
less labor. The CFD analysis was solved by means of ANSYS CFX
software. The fully 3D, Compressible, viscous, turbulent analysis of the fluid (air) flow was solved. The Computational domain
was periodically repeating segment of impeller, diffuser and return channel. The solution was so made on the segment around
one impeller blade and around two return channel vanes.
III. METHODOLOGY
The complete analysis and design of a turbocharger is presented
in this report. The turbocharger analysis was performed utilizing Finite Element Analysis, also known as FEA, which permits
the user to analyze the model by using of software according
required environmental condition and useful parameters that
are necessary to converge on a solution. The analysis for the
turbocharger is constrained by the following two main items:
Compressor impeller and turbine should have similar outside diameters
Turbine and impeller rotate at same rotational velocity

The reason for maintaining similar overall diameters for the turbine and compressor impeller is based on ease of manufacturability and placement in the engine compartment. Having two
very different diameters would prove cumbersome when arranging other components that go in the engine compartment.
This is an example of a design consideration that is dependent
on application. The second constraint is due to the fact that the
impeller and turbine sit on the same shaft. This constraint is
found in most turbo generators.

Fig6-: Bearing housing

CFD Analysis
Computational Fluid Dynamics (CFD) is the present day stateof-art technique in fluid engineering flow analysis. It has wide
range of applications-like pumps, fans, compressors, turbines,
automobiles, process industries, aerospace, in fact in any areas
of study, where there is fluid in motion, air, water, steam etc.
CFD analysis is very useful for predicting pump performance at
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Figure7 -: Flow chart for Design and Simulations of Turbocharger Components by using of design software
IV. ANALYSIS
The work presented in this paper is carried out on and around
a turbocharged; 4-cylinder SI-engine, more detailed data is pre-

Research Paper
sented in Table1. For the main part of the work the engine maintained its production version of turbocharger and manifold. The
turbocharger was a waste gated, single entry, vane less turbine,
as is standard for SI-engines. The manifold was a cast-iron, compact 4-2-1 design.
1. Table. Engine data.
No. cylinders

Bore x stroke [mm]

90 x 78

Valves per cylinder

151

Max torque [Nm]

Max inlet pressure, controlled [Bar]

280
1.8

The initial parameters are given in Table I. With these initial parameters it is possible to start the analysis employing the correct equations in FEA.
2. Table Parameter list for compressor and turbine
Parameter
Volumetric flow rate V
[m3/s]
Mass flow rate m[kg=s]

Compressor

Turbine

NA

0.55

Design rpm

60,000

60,000

Dh2 = 24mm

NA

Isentropic efficiency

Hub Diameter station 2:

Tip diameter station 2:
Tip diameter station 3:
Relative inlet angle

tained. A safety factor of 0.5 is insufficient, and therefore other

materials were selected and retested. A strong alloy was selected in the end after stress analysis results proved a safety factor of 2. Figure 9 shows the safety factor results and Figure 10
shows deformation from the stress analysis on stainless steel
impeller.

4 (pent-roof)

Max power [kW]

Inlet pressure

Volume : 3 | Issue : 5 | May 2014 ISSN No 2277 - 8179

0.33

NA

P01 = P02 = 1.8bar Pin = Pce - Ploss

87%

Dt2 = 67:8mm
Dt3 = 102mm
2 = 143o

Figure 10: Impeller deformation results from stress analysis

Compressor Solution
Before the starting of any solution in ANSYS the meshing of
model is necessary for refinement of solution under the whole
body. The meshing of compressor part is shown in figure 11.

83%
NA
NA
NA

Figure 8: Centrifugal compressor designed with Pro-Engineer

Figur.9: Impeller safety factor of 0.5 from stress analysis

An additional consideration in the design is the impellers material specification. The selected material is dependent on manufacturability, cost, and stress analysis on the impeller. The stress
analysis is performed on ANSYS. ANSYS is capable of performing various stress analysis, one of which is applied centrifugal
forces. This analysis was performed on both the impeller and
turbine rotor. For this part of the design, a stainless alloy was
chosen as the base material; however, after a performed stress
analysis using centrifugal loads, a safety factor of 0.5 was at-

Figure 11. The meshing picture of compressor part

The second step in the process for finding a viable compressor
solution is to solve for the thermodynamic properties of the impeller. Beginning with the inlet temperature and using build in
thermodynamic properties in FEA by using of CFD analysis, enthalpy and density at the inlet are found. Next the geometry is
defined for the inlet and outlet area of blade; however, since no
information is given for the outlet area, a guess value must be
used. In particular, a blade height of 3mm, 4mm, 5mm, 7.5mm,
10mm, and 12.5mm were used. The picture of CFD solution
with assembly of compressor impeller and housing is shown in
figure.12.

Figure 12.Housing of compressor with result of pressure effect analyze by using of CFD Analyze
The pressure increase is attained in the compressor due to the
diverging radial vanes. The vanes extend outward in the radial direction causing the physical area between the vanes to
increase. Due to the continuity equation, this increase in area
forces the velocity of the air to slow, and therefore pressure
to increase. The figure 8 and 9 is shown the velocity effect in
compressor housing. Immediately following the radial impeller
of the compressor, the air enters the diffuser component of the

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Research Paper

turbocharger where the area is increased further between the

diffuser vanes causing a higher pressure increase.

Figure 13. The CFD solution for velocity effect inside the
compressor housing

Figure 14. The CFD solution for velocity effect inside the
compressor housing
V. RESULTS

Figure 16: Mass flow rate Vs Polytropic Efficiency

Figure 17: Mass flow rate Vs Total pressure ratio

V. CONCLUSION
The CFD simulation offers a virtual image of the internal flow in
the machine allowing the analysis and comprehension of more
complex phenomena. An effort was made to model the flow
from inlet to the exit of a centrifugal compressor stage consisting of all the components in place using CFD tools. The vector
plots, contour plots and Stream line plots are generated for better understanding of fluid flow through centrifugal compressor
stage. The results obtained from CFD analysis were validated
with the experimental results for performance parameters such
as polytrophic efficiency, power input, and total pressure ratio.
CFD results on the polytrophic efficiency of a centrifugal compressor predicted the experimental results closely with a variation of 2%. Similarly power input to a centrifugal compressor
stage is predicted by CFD which compares closely with experimental results with a variation of 2.9%. Total pressure ratio of a
centrifugal compressor stage as estimated by CFD tools almost
complies, with negligible variation of 0.03%, with experimental
results.

Figure 15: Efficiency of different stages at different flow

rates

REFERENCE

[1] Dipl.-Ing. Jonas Belz and Dipl.-Ing. Ralph-Peter Mller rapid Design and Flow Simulations for Tubocharger Components EASC ANSYS Conference 2009 RAPID, CFDnetwork Engineering, CFturbo Software & Engineering GmbH | | [2] MeinhardSchobeiri. Turbomachinery Flow
Physics and Dynamic Performance. Springer, 2005 | | [3] L.M. Larosiliere, J.R. Wood, M.D. Hathaway, A.J. Med, and T.Q. Dang. Aerodynamic design study of advanced multistage axial
compressor. Paper TP2002-211568, NASA, December 2002 | [4] D. G. Shepherd. Principles of Turbo machinery. The Macmillan Company, New York, 1956. |

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