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EASC ANSYS Conference 2009 

RAPID DESIGN AND FLOW SIMULATIONS FOR

TUBOCHARGER COMPONENTS 

 Authors

Dipl.-Ing. Jonas Belz CFDnetwork ®  Engineering

Dipl.-Ing. Ralph-Peter Müller CFturbo ® Software & Engineering GmbH

www.cfturbo.de www.cfdnetwork.de

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Rapid Design and Flow Simulations for Turbocharger Components 

26.11.2013 © CFDnetwork® Engineering Seite 226.11.2013 Seite 2

Content

Introduction 03

Design Process and Meshing 04

Performance Prediction Strategy 14

Compressor Example 16

Summary and Prospects 20

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Rapid Design and Flow Simulations for Turbocharger Components 

26.11.2013 © CFDnetwork® Engineering Seite 3

General Design Process

Dimensioning,

Design

CFturbo ®

Grid generation

ICEM-CFD Tetra/Prism,

HEXA, TurboGrid, … 

CAD 

Catia, SolidWorks, 

UG NX, ProE, … 

ProductionOptimization:

interactive or automated

CFD/FEM Simulation 

ANSYS-CFX, Fluent

Measurement 

Rapid Prototyping,

Validation

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Rapid Design and Flow Simulations for Turbocharger Components 

26.11.2013 © CFDnetwork® Engineering Seite 4

Demonstration Case

Compressor Impeller Design Point:

Mass Flow = 0.285 kg/s

Ptot  = 2.25

Speed = 70.000 rpm

• Main Dimensions

• Meridional Contour

• Blade Design• Volute Design

Stage Design

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Rapid Design and Flow Simulations for Turbocharger Components 

26.11.2013 © CFDnetwork® Engineering Seite 5

Fluid Data, Design Point, Parameters to determine Main DimensionsMain Dimensions

Conceptual Design CFturbo ®   – Example: Compressor Impeller1

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Rapid Design and Flow Simulations for Turbocharger Components 

Shape Hub & Shroud, Leading/Trailing Edge Position Meridional Contour

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1 Conceptual Design CFturbo ®   – Example: Compressor Impeller

Hub

Shroud

LEMain

TE

LESplitter

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Rapid Design and Flow Simulations for Turbocharger Components 

26.11.2013 © CFDnetwork® Engineering Seite 7

Blade Form, Velocity Triangle, Leading/Trailing Edge Angle Blade Properties

1 Conceptual Design CFturbo ®   – Example: Compressor Impeller

b

2

b

 

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Rapid Design and Flow Simulations for Turbocharger Components 

26.11.2013 © CFDnetwork® Engineering Seite 9

Thickness distribution, leading/trailing edge shape definitionBlade Profiles

1 Conceptual Design CFturbo ®   – Example: Compressor Impeller

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Rapid Design and Flow Simulations for Turbocharger Components 

26.11.2013 © CFDnetwork® Engineering Seite 10

Complete Design containing Impeller and VoluteStage Design

1 Conceptual Design Cfturbo ®  

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Rapid Design and Flow Simulations for Turbocharger Components 

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22 Pre-Processing

Preparation of Model and Geometry Direct Export to ICEM CFD

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Rapid Design and Flow Simulations for Turbocharger Components 

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Meshing Parameters DialogMeshing ICEM CFD

22 Pre-Processing

• Automated, script-based meshing

• Complete parameter setup in CFturbo ®

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Rapid Design and Flow Simulations for Turbocharger Components 

Tetra/Prism Hexa

(automated) (manual)

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Tetra Mesh with Prism Layers / Hexa MeshMeshing

22 Pre-Processing

Design and meshing for whole

compressor/turbine stage

takes less than 1 hour

Script-based impeller

meshing (ICEM Hexa and

TurboGrid) in development

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Rapid Design and Flow Simulations for Turbocharger Components 

Total Pressure,

Temperature

Static Pressure

Steady Simulation

Frozen Rotor

Turbulence Model: SST

Simulation Setup

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Goals

• Fast performance prediction

•  As many runs as necessary, as

few as possible!

• Comparing two or more designs

• Pressure Ratio

• Efficiency

• Range

Goal, Model, Boundary Conditions Simulation Setup

Simulation3

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Rapid Design and Flow Simulations for Turbocharger Components 

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Pts  = 1.48

Ptot Inlet  = 101325 Pa

→ Pstat Outlet  = 150kPa

Determine Boundary Conditions Simulation Strategy

Simulation3

Pts = 1.48

Simulation StrategyCFturbo’s performance prediction

Possible Unstable

Region

Pstat Outlet = 150kPa

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Rapid Design and Flow Simulations for Turbocharger Components 

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Post-Processing4

Pressure Distribution, Velocity Results

Simulated Cases

Three Impellers, One Volute

1. Impeller without Tip Clearance

2. Impeller with 0.2 mm Tip

clearance

3. Impeller with 0.4 mm Tip

clearance

Hub

Shroud

Tip Clearance

Span

Impeller

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Rapid Design and Flow Simulations for Turbocharger Components 

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Post-Processing4

Tip Vortex in Impeller  Tip Clearance Influence

0.2 mm Tip Clearance 0.4 mm Tip Clearance

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Rapid Design and Flow Simulations for Turbocharger Components 

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Post-Processing4

Differences in Mach Number Distribution Tip Clearance Influence

0.2 mm Tip Clearance 0.4 mm Tip ClearanceNo Tip Clearance

Mach Number

90% Span

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Rapid Design and Flow Simulations for Turbocharger Components 

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Post-Processing4

Tip Clearance Influence, Results vs. Prediction Performance

No Tip Clearance

0.4 mm Tip Clearance

0.2 mm Tip Clearance

CFturbo Prediction

Design Point

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Rapid Design and Flow Simulations for Turbocharger Components 

26 11 2013 © CFDnetwork® Engineering Seite 20

Summary and Prospects

► Parametric/semi-automatic design for radial and mixed flow turbomachines

► Stable process for performance prediction “in one go” 

► Complete process is possible as one batch run

Rapid design process employing CFturbo ®  and ANSYS ® software

► CAE-Process Refinement by CFturbo ®  and CFDnetwork ®  Engineering

► Development of CFturbo ® Software Package (New Release: Fall 2009)

Continuing… 

CFDnetwork 

®

 Engineering