Experimental and numerical investigation on flow angle characteristics of an automotive mixed flow turbocharger turbine

Abstract

To date, turbocharger remains as a key enabler towards highly efficient Internal Combustion Engine. Although the first turbocharger was patented more than 30 years ago, the design is still being improved, thus signifying its importance in modern vehicles. One of the key features that contribute to the challenges in designing highly efficient turbine is the complex nature of the flow field within the turbine stage itself. Experimental method could be used to extract parameters such as pressure and temperature traces but still unable to provide a full description of the flow field. Therefore, the use of Computational Fluid Dynamics (CFD) in resolving this issue is necessary. Out of many feature of fluid flow in turbomachinery, the flow angle at rotor inlet plays significant role in determining turbine efficiency. However, due to geometrical complexity, even at optimum averaged incidence flow angle, there still exist variations that could impair the turbine ability to produce work. This research attempts to provide insight on the complexity of flow angle distribution within the turbocharger turbine stage. To achieve this aim, a numerical model of a full stage turbocharger turbine operating at 30000rpm under its optimum condition was developed. Results indicated that even though use of guide vanes has reduced flow angle fluctuations at mid-span of the rotor inlet from ±10° to only ±1°, significant variations still exist for velocity components in spanwise direction. This in turns effected the distribution of incidence flow angle at the rotor leading edge. In the current research, variation of incidence flow angle in spanwise direction is recorded to be as high as 60°