Inlet recirculation in automotive turbocharger centrifugal compressors

As the designers of modern automotive turbochargers strive to increase map width and lower the mass flow rate at which compressor surge occurs, the recirculating flows at the impeller inlet are becoming a much more relevant aerodynamic feature. Compressors with relatively large map widths tend to have very large recirculating regions at the inlet when operating close to surge; these regions greatly affect the expected performance of the compressor.

This study analyses the inlet recirculation region numerically using several modern automotive turbocharger centrifugal compressors. Using 3D Computational Fluid Dynamics (CFD) and a single passage model, the point at which the recirculating flow begins to develop and the rate at which it grows are investigated. All numerical modelling has been validated using measurements taken from hot gas stand tests for all compressor stages. The paper improves upon an existing correlation between the rate of development of the recirculating region and the compressor stage, which is supported by results from the numerical analysis.

A Numerical and Experimental Assessment of the Use of a Turbine Utilizing Splitter Blades for an Automotive Variable Geometry Turbocharger

Automotive manufacturers require improved part load engine performance to further improve fuel economy. For a swing vane VGS (Variable Geometry Stator) turbine this means a more closed stator vane, to deal with the low MFRs (Mass Flow Rates), high PRs (Pressure Ratios) and low rotor rotational speeds. During these conditions the turbine is operating at low velocity ratios. As more energy is available at high pressure ratios and during lower turbocharger rotational speeds, a turbine which is efficient at these conditions is desirable. Another key aspect for automotive manufacturers is engine responsiveness. High inertia designs result in “turbo lag” which means an increased time before the target boost pressure is reached. Therefore, designs with improved performance at low velocity ratios, reduced inertia or an increased swallowing capacity are the current targets for turbocharger manufacturers.

To try to meet these design targets a CFD (Computational Fluid Dynamics) study was performed on a turbine wheel using splitter blades. A number of parameters were investigated. These included splitter blade merdional length, blade number and blade angle distribution.

The numerical study was performed on a scaled automotive VGS. Three different stator vane positions have been analysed. A single passage CFD model was developed and used to provide information on the flow features affecting performance in both the stator vanes and turbine.

Following the CFD investigation the design with the best compromise in terms of performance, inertia and increased MFP (Mass Flow Parameter) was selected for manufacture and testing. Tests were performed on a scaled, low temperature turbine test rig. The aerodynamic flow path of the gas stand was the same as that investigated during the CFD. The test results revealed a design which had similar performance at the closed stator vane positions when compared to the baseline wheel. At the maximum MFR stator vane condition a drop of −0.6% pts in efficiency was seen. However, 5.5% increase in MFP was obtained with the additional benefit of a drop in rotor inertia of 3.7%, compared to the baseline wheel.

Assessing 1D Loss Models for the Off-Design Performance Prediction of Automotive Turbocharger Compressors

Single-Zone modelling is used to assess three 1D impeller loss model collections. An automotive turbocharger centrifugal compressor is used for evaluation. The individual 1D losses are presented relative to each other at three tip speeds to provide a visual description of each author’s perception of the relative importance of each loss. The losses are compared with their resulting prediction of pressure ratio and efficiency, which is further compared with test data; upon comparison, a combination of the 1D loss collections is identified as providing the best performance prediction. 3D CFD simulations have also been carried out for the same geometry using a single passage model. A method of extracting 1D losses from CFD is described and utilised to draw further comparisons with the 1D losses. A 1D scroll volute model has been added to the single passage CFD results; good agreement with the test data is achieved. Short-comings in the existing 1D loss models are identified as a result of the comparisons with 3D CFD losses. Further comparisons are drawn between the predicted 1D data, 3D CFD simulation results, and the test data using a nondimensional method to highlight where the current errors exist in the 1D prediction.

A numerical study of automotive turbocharger mixed flow turbine inlet geometry for off design performance

Mixed flow turbines represent a potential solution to the increasing requirement for high pressure, low velocity ratio operation in turbocharger applications. While literature exists for the use of these turbines at such operating conditions, there is a lack of detailed design guidance for defining the basic geometry of the turbine, in particular, the cone angle – the angle at which the inlet of the mixed flow turbine is inclined to the axis. This investigates the effect and interaction of such mixed flow turbine design parameters.
Computational Fluids Dynamics was initially used to investigate the performance of a modern radial turbine to create a baseline for subsequent mixed flow designs. Existing experimental data was used to validate this model.
Using the CFD model, a number of mixed flow turbine designs were investigated. These included studies varying the cone angle and the associated inlet blade angle.
The results of this analysis provide insight into the performance of a mixed flow turbine with respect to cone and inlet blade angle.

An Investigation Into Improving Off-Design Performance in a Turbocharger Turbine Utilizing Non-Radial Blading

Off-design performance now plays a vital role in the design decisions made for automotive turbocharger turbines. Of particular interest is extracting more energy at high pressure ratios and lower rotational speeds. In this region of operation the U/C value will be low and the rotor will experience high values of positive incidence at the inlet. The positive incidence causes flow to separate on the suction surface and produces high blade loading at inlet, which drives tip leakage. A CFD analysis has been carried out on a number of automotive turbines utilizing non-radial fibred blading. To help improve secondary flows yet meet stress requirements a number of designs have been investigated. The inlet blade angle has been modified in a number of ways. Firstly, the blading has been adjusted as to provide a constant back swept angle in the span wise direction. Using the results of the constant back swept blading studies, the back swept blade angle was then varied in the span wise direction. In addition to this, in an attempt to avoid an increase in stress, the effect of varying the leading edge profile of the blade was investigated. It has been seen that off-design performance is improved by implementing back swept blading at the inlet. Varying the inlet angle in the span wise direction provided more freedom for meeting stress requirements and reduces the negative impact on blade performance at the design point. The blade leading edge profile was seen to offer small improvements during off-design operation with minimal effects on stress within the rotor. However, due to the more pointed nature of the leading edge, the rotor was less tolerant to flow misalignment at the design point.

A Numerical Study of the Flow Fields in a Highly Off-Design Variable Geometry Turbine

Conventionally, radial turbines have almost exclusively used radially fibred blades. While issues of mechanical integrity are paramount, there may be opportunities for improving turbine efficiency through a 3D blade design without exceeding mechanical limits. Off-design performance and understanding of the secondary flow structures now plays a vital role in the design decisions made for automotive turbocharger turbines. Of particular interest is extracting more energy at high pressure ratios and lower rotational speeds. Operating in this region means the rotor will experience high values of positive incidence at the inlet. A CFD analysis has been carried out on a scaled automotive turbine utilizing a swing vane stator system. To date no open literature exists on the flow structures present in a standard VGT system. Investigations were carried out on a 90 mm diameter rotor with the stator vane at the maximum, minimum and 25% mass flow rate positions. In addition stator vane endwall clearance existed at the hub side. From investigation of the internal flow fields of the baseline rotor, a number of areas that could be optimized in the future with three dimensional blading were identified. The blade loading and tip leakage flow near inlet play a significant role in the flow development further downstream at all stator vane positions. It was found that tip leakage flow and flow separation at off-design conditions could be reduced by employing back swept blading and redistributing the blade loading. This could potentially reduce the extent of the secondary flow structures found in the present study.

An Investigation of Compressor Map Width Enhancement and the Inducer Flow Field Using Various Configurations of Shroud Bleed Slot

This paper describes an investigation of various shroud bleed slot configurations of a centrifugal compressor using CFD with a manual multi-block structured grid generation method. The compressor under investigation is used in a turbocharger application for a heavy duty diesel engine of approximately 400hp. The baseline numerical model has been developed and validated against experimental performance measurements. The influence of the bleed slot flow field on a range of operating conditions between surge and choke has been analysed in detail. The impact of the returning bleed flow on the incidence at the impeller blade leading edge due to its mixing with the main through-flow has also been studied. From the baseline geometry, a number of modifications to the bleed slot width have been proposed, and a detailed comparison of the flow characteristics performed. The impact of slot variations on the inlet incidence angle has been investigated, highlighting the improvement in surge and choked flow capability. Along with this, the influence of the bleed slot on stabilizing the blade passage flow by the suction of the tip and over-tip vortex flow by the slot has been considered near surge.

Experimental and Numerical Benchmarking of an Improved Impeller Meanline Modelling Method for Automotive Turbocharger Centrifugal Compressors

After the development of a new single-zone meanline modelling technique, benchmarking of the technique and the modelling methods used during its development are presented. The new meanline model had been developed using the results of three automotive turbocharger centrifugal compressors, and single passage CFD models based on their geometry.

The target of the current study was to test the new meanline modelling method on two new centrifugal compressor stages, again from the automotive turbocharger variety. Furthermore the single passage CFD modelling method used in the previous study would be again employed here and also benchmarked.

The benchmarking was twofold; firstly test the overall performance prediction accuracy of the single-zone meanline model. Secondly, test the detailed performance estimation of the CFD model using detailed interstage static pressure tappings.

The final component of this study exposed the weaknesses in the current modelling methods used (explicitly during this study). The non-axisymmetric flow field at the leading and trailing edges for the two compressors was measured and is presented here for the complete compressor map, highlighting the distortion relative to the tongue.

An Evaluation of Vaneless Diffuser Modelling Methods as a Means of Improving the Off-Design Performance Prediction of Centrifugal Compressors

An evaluation of existing 1-D vaneless diffuser design tools in the context of improving the off-design performance prediction of automotive turbocharger centrifugal compressors is described. A combination of extensive gas stand test data and single passage CFD simulations have been employed in order to permit evaluation of the different methods, allowing conclusions about the relative benefits and deficiencies of each of the different approaches to be determined. The vaneless diffuser itself has been isolated from the incumbent limitations in the accuracy of 1-D impeller modelling tools through development of a method to fully specify impeller exit conditions (in terms of mean quantities) using only standard test stand data with additional interstage static pressure measurements at the entrance to the diffuser. This method allowed a direct comparison between the test data and 1-D methods through sharing common inputs, thus achieving the aim of diffuser isolation.

Crucial to the accuracy of determining the performance of each of the vaneless diffuser configurations was the ability to quantify the presence and extent of the spanwise aerodynamic blockage present at the diffuser inlet section. A method to evaluate this critical parameter using CFD data is described herein, along with a correlation for blockage related to a new diffuser inlet flow parameter ⚡, equal to the quotient of the local flow coefficient and impeller tip speed Mach number. The resulting correlation permitted the variation of blockage with operating condition to be captured.

Assessment of the double-skin façade passive thermal buffer effect.

Double Skin Façades (DSFs) are becoming increasingly popular architecture for commercial office buildings. Although DSFs are widely accepted to have the capacity to offer significant passive benefits and enable low energy building performance, there remains a paucity of knowledge with regard to their operation. Identification of the most determinant architectural parameters of DSFs is the focus of ongoing research. This paper presents an experimental and simulation study of a DSF installed on a commercial building in Dublin, Ireland. The DSF is south facing and acts to buffer the building from winter heat losses, but risks enhancing over-heating on sunny days. The façade is extensively monitored during winter months. Computational Fluid Dynamic (CFD) models are used to simulate the convective operation of the DSF. This research concludes DSFs as suited for passive, low energy architecture in temperature climates such as Ireland but identifies issues requiring attention in DSF design.

Ectopic bone formation in rapidly fabricated acellular injectable dense collagen-Bioglass hybrid scaffolds via gel aspiration-ejection

Gel aspiration-ejection (GAE) has recently been introduced as an effective technique for the rapid production of injectable dense collagen (IDC) gel scaffolds with tunable collagen fibrillar densities (CFDs) and microstructures. Herein, a GAE system was applied for the advanced production and delivery of IDC and IDC-Bioglass® (IDC-BG) hybrid gel scaffolds for potential bone tissue engineering applications. The efficacy of GAE in generating mineralizable IDC-BG gels (from an initial 75-25 collagen-BG ratio) produced through needle gauge numbers 8G (3.4 mm diameter and 6 wt% CFD) and 14G (1.6 mm diameter and 14 wt% CFD) was investigated. Second harmonic generation (SHG) imaging of as-made gels revealed an increase in collagen fibril alignment with needle gauge number. In vitro mineralization of IDC-BG gels was confirmed where carbonated hydroxyapatite was detected as early as day 1 in simulated body fluid, which progressively increased up to day 14. In vivo mineralization of, and host response to, acellular IDC and IDC-BG gel scaffolds were further investigated following subcutaneous injection in adult rats. Mineralization, neovascularization and cell infiltration into the scaffolds was enhanced by the addition of BG and at day 21 post injection, there was evidence of remodelling of granulation tissue into woven bone-like tissue in IDC-BG. SHG imaging of explanted scaffolds indicated collagen fibril remodelling through cell infiltration and mineralization over time. In sum, the results suggest that IDC-BG hybrid gels have osteoinductive properties and potentially offer a novel therapeutic approach for procedures requiring the injectable delivery of a malleable and dynamic bone graft that mineralizes under physiological conditions

Slot width augmentation in a slotted-wall transonic linear cascade wind tunnel

Transonic tests in linear cascade wind tunnels can suffer
from significant test section boundary interference effects in pitch. A slotted tailboard has been designed and optimised with an in-house Euler numerical method to reduce such ef- fects. Wind tunnel measurements on an overspeed Mach 1.27 discharge from a Rolls-Royce T2 cascade, featuring strong end-wall shock-induced interference, showed a 77% reduction in the flow pitchwise periodicity error with the optimised tail- board, with respect to the baseline open-jet cascade flow. Two-dimensional Euler predictions were also cross-validated against a three-dimensional Reynolds averaged computation, to explore the three-dimensionality of the discharge

Hydraulics of stepped chutes: experimental-numerical-theoretical study

O estudo de escoamentos turbulentos em descarregadores em degraus tem sido um desafio para os investigadores. A macro-rugosidade do leito, a ondulação da superfície livre, a intermitência da localização da secção inicial de entrada de ar e o escoamento bi-fásico a jusante da secção inicial de entrada de ar fazem com que a caracterização do escoamento deslizante sobre turbilhões em descarregadores em degraus não seja simples. Actualmente, é possível combinar técnicas de medição fiáveis com simulações numéricas e análise teórica. Nesta dissertação, o estudo experimental baseia-se em resultados experimentais obtidos em duas instalações experimentais: a instalação A, do Laboratório Nacional de Engenharia Civil (LNEC), dotada de um descarregador em degraus com declive de 1V:0.75H e a instalação B, do Instituto Superior Técnico (IST), dotada de um descarregador em degraus com declive de 1V:2H. Uma sonda de ar, um tubo de Pitot modificado e vários hidrómetros permitiram o estudo do escoamento deslizante sobre turbilhões mono- e bifásico ao longo do descarregador em degraus da instalação A. Na bacia de dissipação de energia, a observação visual do escoamento foi auxiliada pelas leituras efectuadas em tomadas de pressão localizadas na soleira da bacia e pelas leituras da altura do escoamento efectuadas em réguas graduadas localizadas nas paredes da bacia. Na instalação B foram utilizados um tubo de Pitot e vários hidrómetros para estudar a região não arejada do escoamento deslizante sobre turbilhões no descarregador em degraus. O estudo numérico é baseado em simulações numéricas da região não arejada do escoamento deslizante sobre turbilhões sobre descarregadores em degraus com o código comercial de CFD FLOW-3D® de modo a reproduzir as condições ensaiadas experimentalmente. As simulações beneficiaram da técnica de blocos múltiplos (multi-block) num sistema de coordenadas cartesianas, da determinação da superfície livre pelo método TruVOF e da utilização de dois modelos de turbulência: os modelos k- e RNG k-. Por último, o estudo teórico consistiu em desenvolver um modelo simplificado 1D para determinar as características hidráulicas principais do trecho não arejado do escoamento deslizante sobre turbilhões em descarregadores em degraus. O modelo foi desenvolvido a partir das equações de Navier-Stokes, conjuntamente com resultados experimentais e numéricos. Os resultados apresentados nesta dissertação contribuem para o conhecimento do escoamento deslizante sobre turbilhões em descarregadores em degraus, nomeadamente na região não arejada, na secção inicial de entrada de ar e na região arejada. A hidráulica dos dissipadores de energia a jusante de descarregadores em degraus, em particular das bacias tipo III do USBR, é também objecto de estudo. Em relação à região não arejada do escoamento em descarregadores com declive acentuado, e com base em resultados experimentais e numéricos, são propostas expressões para estimar o desenvolvimento da altura equivalente de água, da espessura da camada limite, da concentração média de ar, do coeficiente de energia cinética, da dissipação de energia, do factor de resistência e do coeficiente n da fórmula de Manning. São ainda propostas expressões adimensionais para a energia cinética turbulenta e sua dissipação. Para declives moderados, são propostas expressões para estimar o desenvolvimento da altura equivalente de água, do coeficiente de energia cinética e da energia específica residual. São ainda apresentados valores do expoente 1/N da expressão adimensional da distribuição de velocidades, quer para descarregadores com declive acentuado quer com declive moderado. Em conformidade com outros estudos centrados em escoamentos de parede e com derivações teóricas, para a região não arejada do escoamento em descarregadores em degraus de acentuado declive, observa-se que o factor de resistência depende da macro-rugosidade criada pelos degraus e da geometria da secção transversal e que o coeficiente n da fórmula de Manning aumenta com a rugosidade. A descrição estatística da turbulência do escoamento é igualmente explorada, contribuindo para o conhecimento da estrutura do escoamento. Observou-se que para números de Reynolds rugoso não superiores a 6.8x104 a energia cinética turbulência e a sua dissipação cumprem leis de semelhança. Estas expressões adimensionais estão de acordo com os resultados obtidos por outros autores para escoamentos completamente desenvolvidos em canais abertos e no escoamento em rios com leito de gravilha. Em acréscimo, a taxa de dissipação de energia, quer para descarregadores de declive acentuado quer de moderado declive, é baixa. Por último, observa-se que os valores da média temporal da concentração de ar entre 0 e 1 medidos na região não arejada do escoamento dizem respeito não só ao ar capturado entre ondas de água, na zona de ondulação da superfície livre, mas também ao ar emulsionado no escoamento, i.e., sob a forma de bolhas de ar, quando perto da secção média inicial de entrada de ar, devido à diferença entre localizações instantânea e média temporal. Foram revistas metodologias e fórmulas para estimar a localização da secção inicial de entrada de ar e apresentadas expressões para estimar a concentração média de ar e a altura equivalente de água nessa secção. Relativamente à região de escoamento arejado em descarregadores em degraus com declive acentuado, os resultados experimentais apresentados nesta dissertação permitiram estimar a influência da definição da superfície livre nos parâmetros hidráulicos da região do escoamento arejado e estimar a máxima elevação do escoamento nesta região do escoamento. Com base nos resultados experimentais obtidos na bacia de dissipação de energia do tipo III do USBR localizada a jusante do descarregador em degraus da instalação A, observou-se que os perfis da altura piezométrica e da altura do escoamento tendem a seguir o perfil recomendado pelo USBR para bacias tipo III. A excepção ocorre à entrada da bacia, onde as alturas piezométricas apresentadas nesta dissertação excedem largamente as apresentadas pelo USBR. É ainda observado que, tal como entre as bacias tipo I e tipo III do USBR, o ressalto hidráulico estabiliza muito mais rapidamente numa bacia tipo III a jusante de um descarregador em degraus do que uma bacia tipo I a jusante do mesmo descarregador em degraus. Finalmente, observa-se que os blocos de amortecimento a colocar no descarregador não têm influência visível nos resultados da altura piezométrica nem da altura do escoamento ao longo da bacia. Relativamente às simulações numéricas do escoamento não arejado, a proximidade entre resultados experimentais e numéricos permite validar o modelo teórico e a integração numérica usados no FLOW-3D®. As simulações desenvolvidas também mostraram que o modelo de turbulência k- permite representar as características do escoamento não arejado em descarregadores em degraus, uma vez que não foram observadas diferenças significativas entre as simulações com este modelo e com o modelo RNG k-. Finalmente, observou-se que o modelo de entrada de ar usado no FLOW-3D® é válido para estimar a localização da secção inicial de entrada de ar. Por último, a proximidade entre os resultados obtidos da aplicação do modelo teórico desenvolvido no âmbito desta dissertação e os resultados experimentais indica que as hipóteses e simplificações consideradas no desenvolvimento do modelo são adequadas.

Accidental release of hazardous gases: modelling and assessing risk

The renewed concern in assessing risks and consequences from technological hazards in industrial and urban areas continues emphasizing the development of local-scale consequence analysis (CA) modelling tools able to predict shortterm pollution episodes and exposure effects on humans and the environment in case of accident with hazardous gases (hazmat). In this context, the main objective of this thesis is the development and validation of the EFfects of Released Hazardous gAses (EFRHA) model. This modelling tool is designed to simulate the outflow and atmospheric dispersion of heavy and passive hazmat gases in complex and build-up areas, and to estimate the exposure consequences of short-term pollution episodes in accordance to regulatory/safety threshold limits. Five main modules comprising up-to-date methods constitute the model: meteorological, terrain, source term, dispersion, and effects modules. Different initial physical states accident scenarios can be examined. Considered the main core of the developed tool, the dispersion module comprises a shallow layer modelling approach capable to account the main influence of obstacles during the hazmat gas dispersion phenomena. Model validation includes qualitative and quantitative analyses of main outputs by the comparison of modelled results against measurements and/or modelled databases. The preliminary analysis of meteorological and source term modules against modelled outputs from extensively validated models shows the consistent description of ambient conditions and the variation of the hazmat gas release. Dispersion is compared against measurements observations in obstructed and unobstructed areas for different release and dispersion scenarios. From the performance validation exercise, acceptable agreement was obtained, showing the reasonable numerical representation of measured features. In general, quality metrics are within or close to the acceptance limits recommended for ‘non-CFD models’, demonstrating its capability to reasonably predict hazmat gases accidental release and atmospheric dispersion in industrial and urban areas. EFRHA model was also applied to a particular case study, the Estarreja Chemical Complex (ECC), for a set of accidental release scenarios within a CA scope. The results show the magnitude of potential effects on the surrounding populated area and influence of the type of accident and the environment on the main outputs. Overall the present thesis shows that EFRHA model can be used as a straightforward tool to support CA studies in the scope of training and planning, but also, to support decision and emergency response in case of hazmat gases accidental release in industrial and built-up areas.

Étude numérique des phénomènes transitoires dans une turbine axiale de type hélice durant l’emballement

Ce mémoire présente l’étude numérique d’un emballement de turbine hydraulique axiale à échelle modèle. Cet état transitoire est simulé du point de meilleur rendement jusqu’à l’atteinte de 95% de la vitesse d’emballement. Pour ce faire, une méthodologie numérique est développée à l’aide du logiciel commercial ANSYS CFX en utilisant une approche "Unsteady Reynolds Averaged Navier-Stokes" avec modèle de turbulence k-ε. Cette méthodologie numérique a été validée grâce à des mesures expérimentales de pression acquises en situation d’emballement sur les aubes d’une roue de turbine axiale étudiée au Laboratoire de Machines Hydrauliques de l’Université Laval. La validation des simulations numériques a été réalisée grâce à des comparaisons dans les domaines temporel et fréquentiel entre les pressions mesurées expérimentalement et calculées numériquement. Les analyses fréquentielles en transitoire ont été effectuées à l’aide de transformées en ondelettes afin de représenter l’évolution temporelle du spectre de fréquence. Des analyses qualitatives de phénomènes hydrauliques prenant place dans la turbine sont aussi présentées. Les analyses effectuées ont permis de confirmer le développement d’un tourbillon en précession par rapport à la roue dans l’aspirateur provocant les fluctuations de pression dominantes à des fréquences subsynchrones. La comparaison entre les données expérimentales et numériques a permis de valider une stratégie de simulation transitoire et d’en définir les limites en vue de prochaines simulations d’emballement. Des tests supplémentaires sont suggérés pour améliorer la précision ou le niveau de confiance de la méthode.