Impellers, which are part of the turbochargers in many transport and agricultural vehicles such as cars, trucks, tractors, boats as well as lawnmowers, are parts where monitoring the efficiency of design and subsequent manufacturing is very important. In order to maximize the efficiency of the compressor stage, many iterations in impeller blade geometry design must be performed to achieve the operating conditions in terms of both performance and strength. Impeller manufacturing is then strongly dependent on the impeller blade geometry design. Manufacturing efficiency varies greatly if the impeller is designed with the blades made up of complex surfaces (requires more machining time) or ruled surfaces (requires less machining time). However, the two impeller geometries have a common element that strongly influences their manufacturing efficiency – the impeller blade fillet radius. The choice of the blade fillet radius value is very limited by the impeller blade geometry design. Therefore, this paper proposes a method to determine the blade fillet radius value in order to achieve an efficient impeller geometry in terms of manufacturing efficiency at the impeller design stage. The method is verified on the example of milling several impeller variants.

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