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Nozzleless housings for turbocharger turbines accelerate and guide flow into downstream rotors. Their design affects the aerodynamic performance and reliability of the turbines. Due to the three-dimensional nature of the volute of the housings, turbine housing volute design is largely based on extended 1D theories and trial-and-error method. In this paper, a detailed description of an extended two-dimensional theory for volute design is given, including its numerical implementation. The method is then applied to design a twin-entry turbine housing for a turbocharger turbine under both equal and unequal admissions, to replace a highly optimized, manually designed housing. The results show that the new volute achieves the same turbine aerodynamic performance as the manually optimized volute with greatly reduced design time, and it also generates more uniform rotor inlet condition with lower pressure excitation force. A breakdown of the stage loss shows that the loss in the new volute housing is larger than that in the manual housing due to its smaller overall dimensions, but the losses inside rotor and downstream diffuser are both reduced due to the more uniform volute exit flow. A discussion on the secondary flow in the two volutes is carried out to show how the volute geometry, through influencing the radial discharge from the volute exit, affects this flow. A further discussion on the flow angle jump around the tongue is placed at the end of the paper to show the mechanism of this jump, how to control it in volute design, and to offer a way forward to improve the volute design method.
Nozzleless housings for turbocharger turbines accelerate and guide flow into downstream rotors. Their design affects the aerodynamic performance and reliability of the turbines. Due to the three-dimensional nature of the volute of the housings, turbine housing volute design is largely based on extended 1D theories and trial-and-error method. In this paper, a detailed description of an extended two-dimensional theory for volute design is given, including its numerical implementation. The method is then applied to design a twin-entry turbine housing for a turbocharger turbine under both equal and unequal admissions, to replace a highly optimized, manually designed housing. The results show that the new volute achieves the same turbine aerodynamic performance as the manually optimized volute with greatly reduced design time, and it also generates more uniform rotor inlet condition with lower pressure excitation force. A breakdown of the stage loss shows that the loss in the new volute housing is larger than that in the manual housing due to its smaller overall dimensions, but the losses inside rotor and downstream diffuser are both reduced due to the more uniform volute exit flow. A discussion on the secondary flow in the two volutes is carried out to show how the volute geometry, through influencing the radial discharge from the volute exit, affects this flow. A further discussion on the flow angle jump around the tongue is placed at the end of the paper to show the mechanism of this jump, how to control it in volute design, and to offer a way forward to improve the volute design method.
In order to meet the higher design requirements of radial turbines, it is necessary to clearly understand the impact of different design parameters on turbine performance. The A/R distribution is one of the most important design parameters for the radial turbine volute, but there are few studies on it. To clarify the effect of A/R distribution on turbine efficiency and blade excitation force, a detailed comparative study is carried out. An experimentally validated numerical method is used, and steady and unsteady CFD simulations are conducted in this study. The results show that the volute A/R distribution has a significant effect on the turbine efficiency, while a linear distribution can provide a more uniform inlet condition and thus improve the rotor efficiency. The flow parameters fluctuated significantly at the volute tongue. Although the efficiency is not sensitive to this fluctuation, it directly affects the excitation force on the rotor blades. The volute with S-shaped A/R distribution produces the smallest excitation force due to the smallest fluctuation. Two new A/R distributions are presented which combine the advantages of linear and S-shaped or convex A/R distributions with high efficiency and low excitation force. It is suggested that the A/R should be close to the linear distribution and decreases rapidly before the tongue.
The nozzleless volute housings can generate non-uniform flow distributions to the downstream radial turbine rotors, which not only affects turbine aerodynamic performance but also poses a threat to the fatigue life of the rotors. It is believed that the housing tongue is the main factor in generating this non-uniformity. Tongue design is based on experience and the geometric parameters of tongue, such as the distance between the tongue and rotor, the thickness of the tongue, and tongue shape are to be specified in the design. A few studies on housing tongue can be found in the literature, but in these investigations of the influences of tongue geometric parameters, factors such as mass flow rate and volute A/R distribution were not kept constant, thus introducing additional factors and reducing the persuasiveness of the results. Therefore, three new housings with different tongue-rotor distances are designed with a two-dimensional method for comparative CFD studies. The results indicate that when the mass flow of the turbines is kept, the distance between the tongue and the rotor has little impact on the turbine efficiency (about 0.1%), while the blade excitation forces from the housing increase with the decrease of the distance by more than 50%. Two further new housings are then created by modifying the housing inlet pipe to minimize tongue thickness, one of the housings is more practical with a short and thin tongue. CFD results indicate 0.2%∼0.4% improvement of turbine efficiency and reduction of housing excitation forces by more than 50% using these two thin tongue housings.
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