AcousticandPerformanceOptimizationofaTurbocharger

The improvement of the existing design cycle may have certain limitations. Finding the optimum design for a turbo machinery blade is a significantly complex task, involving numerous different objectives and constraints coming for various disciplines. In addition, there is a multifaceted relationship between performance and design variables. To make things more complex, limited engineering time is usually assigned to a design task, which does not allow the designers to take full advantage of the whole set of dataobtainedbyCFD,structural,andexperimentalresultsandconclusionsfromalimitedsetofdataare drawn. NUMECAs optimization toolbox for turbomachinery FINE/Design 3D which offers a seamless process chain, gives a sound response to this challenge. The suit covers what is needed from parameterization (AutoBlade), mesh generation (AutoGrid) and analysis (FINE/Turbo) to optimization and data base creation.WithregardstotheFINE/Design3Doptimizationtool,alargenumberofkeyfunctionalitiescan be listed. It integrates a genetic algorithm to approach a global optimum of arbitrary combinations of userdefinable objective functions. In addition, it takes into account userdefinable secondary boundary conditions and restrictions (thickness distributions, momentum of inertia, inlet/outlet metal angle distribution). The Artificial Neuronal Network (ANN) connects aerothermodynamic properties and geometrical parameters. A high number of free parameters can be defined (~40). It deals with multi operatingpointoptimization(turbocharger),multirowoptimization(axialcompressors)andmultimesh optimization(radialinletguidevane). In the study case shown below, numerous objectives have been defined. Amongst others, the Total Pressure Ratio and the Efficiency have been increased over several operating points. Also, the surge margin has been extended. What is unique to this optimization is that the acoustic signature of the compressor has been drastically reduced, and that is an objective, which is usually in contradiction with the above mentioned. All the objectives of this optimization were fulfilled or even exceeded. Several designs that satisfy or even overshooting all optimization criteria were identified while the selection of thefinaldesigndependsonthepreferencesand/orthemanufacturingconstraints.
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Configurationofthemesh

Ahighqualitymeshwasobtained,withhighstaggerH&I,pointtopointperiodictopology,consistingof 21blocksand1.100.000points.Themeshgenerationtimewaslessthan2minutesusingNUMECAs structuredautomaticmeshgeneratorAutoGrid.

Convergence
NUMECAsgridgenerationsystems,combinedwithamajorincreaseinCPUwithitsCPUBooster, guaranteeasignificantspeedupofyourengineeringandCPUtime.

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Results
Ascanbededucedbythestaticpressurecontourdistributionsandplotsattheshroud,theamplitudeof preshock pressure wave in the optimized Design C was reduced significantly as compared with the originalgeometry.Thepressureratioofthebestdesigncouldbeincreasedby15%.

Original

DesignC

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The instantaneous pressure fluctuations created by the impeller is significantly reduced by the optimiseddesign.

UnsteadyPressureFluctuations Original CalculationsperformedbyNUMECAIngenieubro,bycourtesyofFVV DesignC

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