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Research Papers

Blade Excitation in Pulse-Charged Mixed-Flow Turbocharger Turbines

[+] Author and Article Information
Stephan M. Senn1

Research and Development Turbochargers, ABB Turbo Systems Ltd., CH-5401 Baden, Switzerlandstephan.senn@ch.abb.com

Martin Seiler, Ottmar Schaefer

Research and Development Turbochargers, ABB Turbo Systems Ltd., CH-5401 Baden, Switzerland

1

Corresponding author.

J. Turbomach 133(2), 021012 (Oct 21, 2010) (6 pages) doi:10.1115/1.4001186 History: Received July 24, 2009; Revised September 08, 2009; Published October 21, 2010; Online October 21, 2010

In this article, a fully three-dimensional computational modeling approach in the time and frequency domain is presented, which allows to accurately predicting fluid-structure interactions in pulse-charged mixed-flow turbocharger turbines. As part of the approach, a transient computational fluid mechanics analysis is performed based on the compressible inviscid Euler equations covering an entire engine cycle. The resulting harmonic orders of aerodynamic excitation are imposed in a forced response analysis of the respective eigenvector to determine effective stress amplitudes. The modeling approach is validated with experimental results based on various mixed-flow turbine designs. It is shown that the numerical results accurately predict the measured stress levels. The numerical approach can be used in the turbine design and optimization process. Aerodynamic excitation forces are the main reason for high cycle fatigue in turbocharger turbines and therefore a fundamental understanding is of key importance.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Computational domain and discretization of the mixed-flow turbine stage, including a twin volute with two separate gas inlets, stator, and rotor

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Figure 2

Transient total pressure and temperature boundary conditions at the outer inlet (full line) and inner inlet (dashed line) of the twin volute of rotor design A for an entire engine cycle. (a) Total pressure boundary condition of case A8 (resonance f1.6). (b) Total temperature boundary condition of case A8. (c) Total pressure boundary condition of case A9 (resonance f1.7). (d) Total temperature boundary condition of case A9.

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Figure 3

Variation of the local excitation amplitude on the suction side and pressure side of the rotor blade of turbine design A. Amplitudes are scaled with the maximum amplitude of case A4. (a) Case A1, suction side. (b) Case A1, pressure side. (c) Case A4, suction side. (d) Case A4, pressure side.

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Figure 4

Resulting rotor blade force for (a) an entire engine cycle, (b) 1/16 engine cycle, and (c) one single turbocharger revolution, exemplified by case A8 (rotor design A)

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Figure 5

Aerodynamic excitation amplitudes at the rotor blade surface under pulse-charged conditions, exemplified by case A8 (rotor design A).

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Figure 6

Measured maximum stress amplitudes for each rotor blade (scaled with σ). (a) Rotor design A, resonance f1.6. (b) Rotor design A, resonance f1.7. (c) Rotor design B, resonance f1.5.

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Figure 7

Maximum stress amplitudes (scaled with σ): computed (circles) versus measured (lines) values. Ranges of experimental results indicate the maximum, average, and minimum blade-to-blade maximum stress amplitudes. (a) RD A, RS f1.6, A1–A4. (b) RD A, RS f1.7, A5–A7. (c) RD B, RS f1.5, B1–B4.

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