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EXIT FROM ROTOR
HUB MEAN TIP
DIRECTION OF ROTATION
b
TiP
MEAN <rt:INLET
ArP
FIG. 2 RADIAL AND AXIAL TURBINE ROTORS
HUB
Another method of reducing inertia is the use L.E. Dia./Chord .10 .06 .03
of an axial flow turbine rotor rather than the Chord (Inches) .35 .34 .37
heavier radial inflow turbine rotor in production
today. This report describes the design, rig tests FIG. 4 BLADE SECTIONS
as well as the dynamometer transient and steady-
state testing of an axial flow turbocharger.
DISCUSSION to obtain the same 6 psig (41.4 kPa) boost at the
same 3000 r.p.m. engine speed as the radial flow
DESIGN turbine, and both turbines would utilize a waste-
gate to limit boost at the higher engine speeds.
As part of an investigation on turbocharger A comparison of the meridonal flow path of the two
lag, an axial-flow turbine was designed to replace turbines is shown in Figure 1. Both turbines used an
a radial-flow turbine in a turobcharger matched for inlet volute or scroll rather than nozzle vanes to
use on a 2.3L engine. Both turbines were to operate generate the angular momentum energy needed at inlet
with the same centrifugal compressor and the same to the turbine rotor. The axial flow turbine has
bearing system. The axial flow turbine was designed
about the same tip diameter as the radial turbine.
24
22
20
18
16
o 14
12
2 10
8
w 6
U 4
U
2
0
I.0
FIG. 5 ROTOR AND HOUSING ASSEMBLIES .011 to .013 inches (0.28 to 0.33 mm) in keeping
with conventional turbocharger practice for radial
TABLE 1 INERTIA AND WEIGHT COMPARISON flow turbines of this size. Hot running tip clear-
ance was estimated at 3.5% of the blade span and
Inertia Weight using information from (22), the tip clearance loss
2
Rotating Assembly Contains Ft-Lb-Sec Lbs. would result in a 6% reduction in turbine efficiency.
At 6000 engine rpm the turbo speed will increase to
Metallic Radial Turbine 132 x 10 -7 .37 150,000 rpm and a finite element analysis showed the
disc stresses at this speed to be about 27,000 psi
Ceramic Radial Turbine 69 x 10 -7 .22 (187,000 kPa). Peak blade stresses at the blade
root would be about 30,000 psi (230,000 kPa) at
Metallic Axial Turbine 68 x 10 -7 .27 this condition. Less than the aerodynamically
optimum number of blades were selected for this
Ceramic Axial Turbine 49 x 10 -7 .18 design for the following reasons:
Zvi
cn
cr 1.0 40? 1 1
.2 .4 .6 .8 1.0 a.
outlet. Instrumentation included speed, compressor FIG. 8 STEADY-STATE DYNAMOMETER TEST RESULTS
airflow, compressor inlet and outlet pressures and
temperatures, turbine airflow and turbine inlet ratio of 0.5 and falls off on either side of this
and outlet pressures and temperatures.
value. The turbine operates at low velocity ratios
at low engine speeds and usually reaches the design
The flow characteristics of the axial flow
value at the speed where the wastegate opens. The
turbine are shown in Figure 6, along with the flow
scatter in the test data reflects the fact that the
characteristics of the equivalent radial flow tur-
bench test did not employ a high-speed dynamometer,
bine. Turbine flow is a function of not only
so the efficiency was calculated from the power
pressure ratio, as shown here, but also of cor-
rected turbine speed. The test facility was limited, absorbed by the compressor and bearings. Extensive
use of insulation and extremely low turbine inlet
however, so only a small range of each flow charac-
teristic could be obtained at each speed. This data temperatures were used during efficiency measure-
has been condensed in Figure 6 to show only one flow ments to minimize heat conduction errors. Measure-
characteristic, which represents the compressor- ment under normal conditions would have resulted in
turbine match point, for each corrected speed. The a higher, erroneous efficiency because of these
errors. Different compressors were used as loading
flow data shown here was obtained from the axial
devices to extend the range of test data. The peak
turbine rotor and one of several volutes evaluated
axial turbine efficiency of about 75% was similar to
in the bench test program. This combination most
the peak efficiency measured on the baseline radial
closely matched the flow characteristics of the
radial flow turbine. turbine. It is also about equal to peak efficiency
data for turbocharger radial turbines as presented
in the literature (15,16,24,25).
Figure 7 shows the total-to-static axial turbine
efficiency as measured on the bench test plotted It should be emphasized that competitive effi-
against isentropic velocity ratio. The peak effi- ciencies in the axial turbines can only be obtained
ciency occurs near the design isentropic velocity at moderate levels of pressure ratio or boost. At
50 50
40 40
30 30
20 20
10 I0
0 0
0 0
0 125
c) 0 125
2 100
T
2 I00
SPEED
a ra_
2 75 RADIAL TURBINE 75
50 VAXIAL TURBINE RADIAL TURBINE
50
cl- AXIAL TURBINE
25 SPEED
op 25
0 0
co 0 0
cc cr
0 1 2 0 I 2
ELAPSED TIME SECONDS ELAPSED TIMESECONDS
FIG. 9 TRANSIENT TEST RESULTS AT 1500 RPM FIG. 11 TRANSIENT TEST RESULTS AT 2500 RPM
50 50
40 40
30 MANIFOLD 30
ABSOLUTE
20 PRESSURE 20
10 10
0 0
0 0
0 125
0 0 125
100 .1. 100
a_
cc cc 75
75
LA 50 LU 50
U
a-
m 25 cn 25
0 0
co
0 cc 0
I 2 0 I 2
ELAPSED TIMESECONDS ELAPSED TIMESECONDS
FIG. 10 TRANSIENT TEST RESULTS AT 2000 RPM FIG. 12 TRANSIENT TEST RESULTS AT 3000 RPM
high pressure ratios the efficiency of the axial octane aircraft gasoline engines or heavy-duty truck
turbine will start to deteriorate because of ex- diesel engines, higher levels of boost are employed
cessively high aerodynamic stage loadings. A so a radial flow turbine must be used in these appli-
prohibitively expensive multi-stage axial turbine cations.
would be required to obtain good efficiency at
high pressure ratios. The axial turbine, therefore, DYNAMOMETER TEST
could only be utilized in automotive spark ignition
engines where fuel octane or detonation limitations Following the philosophy of keeping as many of
will restrict boost to moderate values. In high the turbocharger components as possible identically
6 50
1
U)
MN AXIAL ROTOR z
RADIAL ROTOR I a_ 40 FORD-AXIAL
6 5 z
w Lai j
\FLOW
U) cc TURBINE
LiJ z 30 SILICON
a. NITRIDE
ROTOR 46, SILICON
z (Ref. A 001,CARBIDE
Lij
\ ROTOR
22 20
(Ret18)
zw
20
cc
IMROVED
2 10 AERO
DESIGN
(Ref. 15)
1
0
0
20 40
I
60 80
1
100