This paper presents a multidisciplinary design optimization of a turbocharger radial turbine for automotive applications with the aim to improve two major manufacturer requirements: the total-to-static efficiency and the moment of inertia of the radial turbine impeller. The search for the best design is constrained by mechanical stress limitations, by the mass flow and power, and by aerodynamic constraints related to the isentropic Mach number distribution on the rotor blade. The optimization of the radial turbine is performed with a two-level optimization algorithm developed at the von Karman Institute for Fluid Dynamics. The system makes use of a differential evolution algorithm, an artificial neural network (ANN), and a database as a compromise between accuracy and computational cost. The ANN performance predictions are periodically validated by means of accurate steady state 3D Navier-Stokes and centrifugal stress computations. The results show that it is possible to improve the efficiency and the moment of inertia only in a few numbers of iterations while limiting the stresses to a maximum value. Based on the large number of evaluated designs during the optimization, this paper provides design recommendations of a turbocharger radial turbine at least for a good preliminary design.

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This paper presents a multidisciplinary design optimization of a turbocharger radial turbine for automotive applications with the aim to improve two major manufacturer requirements: the total-to-static efficiency and the moment of inertia of the radial turbine impeller. The search for the best design is constrained by mechanical stress limitations, by the mass flow and power, and by aerodynamic constraints related to the isentropic Mach number distribution on the rotor blade. The optimization of the radial turbine is performed with a two-level optimization algorithm developed at the von Karman Institute for Fluid Dynamics (VKI). The system makes use of a Differential Evolution algorithm, an Artificial Neural Network (ANN), and a database as a compromise between accuracy and computational cost. The ANN performance predictions are periodically validated by means of accurate steady state 3D Navier-Stokes and centrifugal stress computations. The results show that it is possible to improve the efficiency and the moment of inertia only in a few numbers of iterations while limiting the stresses to a maximum value. Based on the large number of evaluated designs during the optimization, this paper provides design recommendations of a turbocharger radial turbine at least for a good preliminary design.

Abstract:The adjoint method is considered as the most efficient approach to compute gradients with respect to an arbitrary number of design parameters. However, one major challenge of adjoint-based shape optimization methods is the integration into a computer-aided design (CAD) workflow for practical industrial cases. This paper presents an adjoint-based framework that uses a tailored shape parameterization to satisfy geometric constraints due to mechanical and manufacturing requirements while maintaining the shape in a CAD representation. The system employs a sequential quadratic programming (SQP) algorithm and in-house developed libraries for the CAD and grid generation as well as a 3D Navier-Stokes flow and adjoint solver. The developed method is applied to a multipoint optimization of a turbocharger radial turbine aiming at maximizing the total-to-static efficiency at multiple operating points while constraining the output power and the choking mass flow of the machine. The optimization converged in a few design cycles in which the total-to-static efficiency could be significantly improved over a wide operating range. Additionally, the imposed aerodynamic constraints with strict convergence tolerances are satisfied and several geometric constraints are inherently respected due to the parameterization of the turbine. In particular, radial fibered blades are used to avoid bending stresses in the turbine blades due to centrifugal forces. The methodology is a step forward towards robustness and consistency of gradient-based optimization for practical industrial cases, as it maintains the optimal shape in CAD representation. As shown in this paper, this avoids shape approximations and allows manufacturing constraints to be included.

This paper presents a gradient-based design optimization of a turbocharger radial turbine for automotive applications. The aim is to improve both the total-to-static efficiency and the moment of inertia of the turbine wheel. The search for the optimal designs is accomplished by a high-fidelity adjoint-based optimization framework using a fast sequential quadratic programming algorithm. The proposed method is able to produce improved Pareto-optimal designs, which are trade-offs between the two competing objectives, in only a few iterations. This is realized by redesigning the blade shape and the meridional flow channel for the respective target while satisfying imposed aerodynamic constraints. Furthermore, a comparative study with an evolutionary algorithm suggests that the gradient-based method has found the global Pareto front at a computational cost which is about one order of magnitude lower.