Performance Improvement of a Mixed Flow Turbine Using 3D Blading

Abstract

Mixed flow turbines have reached a level of maturity where iterative performance improvements are small, with real performance benefits coming from better matching to a given application as opposed to improvements in technology. One design feature of mixed flow turbines used to control rotor stress is the radial fibre constraint, wherein blade material is stacked radially outward along the blade. While this constraint yields a mechanical benefit, it constrains the aerodynamic design significantly, with the blade shape defined by one camberline. One potential means of realizing a performance improvement is the use of 3D blading, where the blade is not constrained to a radially fibred structure. In such a design, the blade shape could be freely modified to better control blade loading and secondary flows. This study investigated the viability of such 3D blading through optimization of a state of the art mixed flow turbine. An equivalent design was ensured by maintaining the meridional shape and operating conditions of the baseline wheel, facilitating a fair comparison between the radial and 3D wheels. The paper details the optimization including an innovative constraint-driven geometry modification tool, experimental validation of performance predictions, and an investigation into why 3D blading facilitated a performance improvement. The optimization process identified a performance improvement across the turbocharger operating line. With improvements facilitated through a reduction in tip leakage loss, and improved pressure recovery within the diffuser. Importantly, the optimized design met targets for mass flow, stress levels and modal behaviour, through the novel geometry modification process.

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“…The result of geometric transformations is obtaining a high-quality digital model of Mixed Flow turbines in the SolidWorks CAD system [25]. Thus, it can be concluded that the geometry of Mixed Flow turbines is a complex and complex task, and, accordingly, the creation of digital models of such a product requires the involvement of significant scientific potential and highly qualified technical personnel capable of, on the one hand, performing the role of system integrators and implementers of lean production tasks within Lean-Green practices, and on the other hand, to be able to solve related problems of mechanical engineering technology from the idea to the production of a product using digital services [28,29]. Elliot M. et al [30] noted that, according to modern knowledge about Mixed Flow turbines, the natural advantages of the performance of such turbines are related to better compliance with the given geometric characteristics and not, for example, to improvements in their manufacturing technology.…”