Академический Документы
Профессиональный Документы
Культура Документы
GTIndia2012-9690
EFFECTS OF DISK GEOMETRY ON STRENGTH OF A CENTRIFUGAL COMPRESSOR IMPELLER FOR A HIGH PRESSURE RATIO TURBOCHARGER
ZHENG Xinqian*, JIN Lei, ZHANG Yangjun
State Key Laboratory of Automotive Safety and Energy Tsinghua University, Beijing, China 100084 zhengxq@tsinghua.edu.cn
QIAN Huihua LIU Fenghu
is thus difficult for designers to obtain the optimized designs for their individual, application-specific parametric requirements. If general relationships between geometric parameters of an impeller and its strength can be established, it will be helpful to improve the geometry to decrease the strength. In this paper, a detailed investigation of the effects of five impeller disk geometric parameters on maximum stress and stiffness was performed by using 3-D FEA. Subsequently, geometric parameters of an original impeller were improved on the basis of this analysis to decrease the maximum stress. 2 NUMERICAL METHODS
where u , v and w are the deformations along the directions x , y and z , respectively. The primary aim of static stress analysis is to obtain the distribution of stresses and deformations under the stated loads and boundary conditions. The effects and sensitivities of the principal geometric parameters on the strength of the impeller were investigated by means of a linear elastic FEA, which provides a good understanding into the internal responses of the structure.
and are the normal and shear stress components. Subscripts are used to describe their directions. In the case of linear elastic isotropic 3D solid, the stressstrain relations are given as:
Fbz are the body forces per unit volume acting along the directions x , y , and z , respectively.
x =
where E is Youngs modulus, G is shear modulus, and is Poissons ratio of the material. and are normal strain and shear strain components, respectively. Subscripts are used to describe their directions. The strains induced in the body can be expressed in terms of the deformations, as shown below u v u (7) + x = , xy = x y x v w v (8) + y = , yz = z y y w u w , (9) zx = + z = x z z
1 x ( y + z ) , xy = xy E G yz 1 y = y ( z + x ) , yz = E G 1 z = z ( x + y ) , zx = zx E G
Fig. 1
simulation results, the impeller structure was improved to decrease the stress.
h1
Fig. 2 FEA model of the impeller
h2
h3
The centrifugal compressor impeller is made from aluminum alloy LD7. The Youngs modulus is 74.4 GPa. The Poissons ratio is 0.3 and density is 2760 kg / m , ultimate tensile strength is 412MPa. RESULTS AND ANALYSIS The stress of centrifugal compressor impellers caused by centrifugal force is relative to the rotating speed, disk geometry, and blade geometry. The rotating speed and blade geometry are decisive for the aerodynamic performance and not considered in this paper. The parameters of disk geometry considered in this paper are tip thickness h1 ( h1 / R0 ), rear-disk thickness 3
3
r1 r2
h2 ( h2 / R0 ), rear-disk height h3 ( h3 / R0 ), fillet radius r1 ( r1 / R0 ), and bore radius r2 ( r2 / R0 ). R0 is the radius of the
impeller. The definition of the parameters is shown in Fig. 3.
Fig. 4
Figure 4 shows that the maximum stress under centrifugal load occurs at the core of the disk and the second-maximum stress occurs at the fillet region (marked by A and B in Fig. 4). The maximum stress at the core of the disk (region A) is found to be 360 MPa and the maximum stress at the fillet (region B) is found to be 292 MPa. The impeller has a safety factor of 1.14 (the ratio of the ultimate tensile strength of material 412 Mpa to the maximum stress 360 MPa), which is very small for commercial application. This highlights the requirement of improvement of disk structure. Fig. 3 disk Definition of the geometric parameters of impeller
Firstly, Structural analysis was made on the original impeller, which has being used in market for many years. Then the effect of the five disk geometric parameters on the stress was analyzed. Each one of these geometric parameters is modified keeping other parameters unchanged. Based on the
h1 were calculated and compared with the original impeller. Figure 5 shows the effects of h1 on
11 impellers with different the relative maximum von Mises stress in regions A and B. The
relative maximum stress is the ratio of the maximum stress to the original impellers maximum stress in region A (360 MPa). Figure 6 shows the effects of h1 on the maximum relative deformations along the radial, circumferential and axial directions of the impeller. The relative maximum deformation is the ratio of the maximum deformation to the radius R0 of the original impeller. The results for the original impeller are marked by hollow squares in Figs. 5 and 6.
relative maximum stress
1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Reducing the impeller tip thickness h1 has two advantages. Firstly, it is easier to meet the safety requirements due to a lower level of von Mises stress. In addition, it can prevent blades to scrape the shroud casing, which is caused by deformations of the impeller. Reducing h1 is a feasible and effective approach to improve strength of impellers. However, the impeller should keep a certain tip thickness to meet the requirements of the dynamic balance to remove material. Based on comprehensive considerations of the strength, dynamic balance feasibility and deformations, the tip thickness h1 of the improved impeller is set to 0.013, which is marked by hollow triangles in Figs. 5 and 6.
region A region B
3.2.2 Effects of Rear-Disk Thickness. Stresses and deformations of 13 impellers with various h2 were calculated and compared with the original impeller. Figure 7 shows the effects of
tip thickness
h2 on the relative maximum von Mises stresses in regions A and B. Figure 8 shows the effects of h2 on the
relative maximum deformations along radial, circumferential and axial directions. The results for the original impeller are marked by hollow squares in Figs. 7 and 8.
1.5 1.4 1.3 1.2 1.1 1.0 0.9 0.8 0.7 0 0.04 0.08
rear-disk thickness
region A region B
0.12
0.16
Fig. 6
Effects of
Across the 11 simulated cases, the tip thickness h1 ranges from 0.001 to 0.067. Due to the effect of the centrifugal load caused by the additional mass, it is obvious that the maximum stress values in region A and region B severely increase with increasing h1 . Variations of the maximum stresses at these two regions are quite similar over the entire range of h1 . The von Mises equivalent stress in region A is between 0.78 and 1.12 times that of the original impeller. Variations of h1 also lead to large changes in deformations along the radial, circumferential and axial directions. It can be seen that the maximum circumferential deformation decreases but the axial deformation increases with increasing h1 . The effect of deformation is comparably small.
0.04
0.08
rear-disk thickness
0.12
0.16
h1 on radial
Fig. 8
The parameter range for the rear-disk thickness h2 is 0 0.160. Due to the centrifugal load being shared by the rear-disk, the maximum stress in region A decreases severely with increasing
influence on maximum stress when h2 0.080 . The von Mises equivalent stress in region A is between 1.44 to 0.94 times that of the original impeller. In region B,
h2 has a negligible influence on the maximum stress over the entire range of h2 . Variations of h2 also lead to some changes in deformations h2 . The
0.3
0.4
along the radial, circumferential and axial directions. It can be seen that the maximum circumferential deformation increases, while the axial deformation decreases with increasing effect of
Fig. 10
h2 on radial deformation is relatively not significant. Mass and inertia increase with increasing h2 , while the
stress decreases. Based on comprehensive
h3 ranges from
0.027 to 0.33. It can be observed that the maximum stress in region B decreases with increasing h3 . It should be noted that the maximum stress in region A decreases with increasing when
maximum
considerations of strength and mass, the rear-disk thickness h2 is set to 0.080 for the improved impeller, which is same as that of the original impeller. 3.2.3 Effects of Rear-Disk Height. Stresses and
h3
h3 were
then increases strongly when h3 0.267 due to the additional centrifugal load caused by additional material. The von Mises equivalent stress in region A is between 0.98 and 1.12 times that of the original impeller. However, the minimum stress was obtained when h3 = 0.160 .Variations in
changes in deformations along the radial, circumferential and axial directions. It can be seen that the maximum circumferential deformation increases while the axial deformation decreases with increasing h3 . The effect of radial deformation is comparably small. Considering the effect of increasing
the relative maximum deformations along the radial, circumferential and axial directions. The results for the original impeller are marked by hollow squares in Figs. 9 and 10.
1.2
relative maximum stress
h3 on
region A region B
impeller is selected to be 0.160, which is marked by hollow triangles in Figs. 9 and 10. 3.2.4 Effects of Fillet Radius. Stresses and deformations for 9 values of r1 were calculated and compared with the original
0.2
rear-disk height
0.3
0.4
Fig. 9
Effects of
impeller
impeller. Figure 11 shows the effects of r1 on the relative maximum von Mises stresses in regions A and B. Figure 12 shows the effects of r1 on the relative maximum deformations along the radial, circumferential and axial directions. The results for the original impeller are marked by hollow squares in Figs. 11 and 12.
1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0 0.1 0.2 0.3
fillet radius
the relative maximum von Mises stresses in regions A and B. Figure 14 shows the effects of r2 on the relative maximum deformations along the radial, circumferential and axial directions. The results for the original impeller are marked by hollow squares in Figs. 13 and 14.
1.1
relative maximum stress
0.4
0.5
0.6
Fig. 12
Effects of
The fillet radius r1 ranges from 0.07 to 0.53. Due to the effect of a larger fillet radius, the maximum stress in region B decreases significantly with increasing r1 . On the other hand, variations in the maximum stress in region A are quite slight over the entire range of r1 / R0 .The minimum stress can be obtained when r1 = 0.267 . Variations in r1 also lead to little changes in deformations along the radial, circumferential and axial directions. It can be seen that the maximum circumferential deformation increases with increasing r1 while the axial deformation decreases. The effect of r1 on radial deformation is relatively insignificant. Generally speaking, the maximum stress in region A is higher than that in region B, so the increase of r1 is insignificant for the overall strength of impellers. The fillet radius of the improved impeller is selected to be r1 = 0.267 , which is marked by hollow triangles in Figs. 11 and 12. 3.2.5 Effects of Bore Radius. The stresses and deformations of 12 impellers with varying r2 were calculated and compared with the original impeller. Figure 13 shows the effects of
0.1
0.15
Fig. 14
Effects of
r2 is varied from 0 to 0.150. It can be noted that r2 decreases with decreasing r2 . However, the
The bore radius maximum stress in region A decreases significantly with decreasing r2 when r2 0.040 . The von Mises equivalent stress in region A is 0.53 to 1.03 times that of the original impeller. That is, the von Mises equivalent stress in region A is found to be 0.53 times the original impeller when r2 = 0 (with no bore). The maximum stress in region A is smaller than that in region B for r2 0.030 . It should also be noted that r2 has little influence upon the maximum stress in region B over the entire range of r2 . Variations of r2 also lead to some changes in deformations along the radial, circumferential and axial directions. It can be seen that the axial deformation decreases obviously with increasing r2 . The effect of r2 on radial and circumferential deformation is not significant.
r2 on
Although the maximum stress in region A decreases with decreasing r2 , a small r2 means a slim shaft. Furthermore, it is difficult to redesign a new shaft system to adapt to the changes of the bore radius. The bore radius r2 of the improved impeller is selected to be 0.120, which is same as the original impeller that has been used for many years.
Fig. 16
parameters
h1 h2
h3
r1
r2
Figure 15 shows that the stress distribution in the improved impeller I is similar to that of the original impeller, with the same stress concentration regions, but the maximum stress level is reduced significantly. The calculations show encouraging results: the maximum von Mises equivalent stress in region A is 293MPa, a decrease of 19% compared to the original impeller. The von Mises equivalent stress in region B is 215MPa, a decrease of 26%. Figure 16 shows that the maximum von Mises equivalent stress in region A in the improved impeller II is 180MPa, a decrease of 50% compared to the original impeller. The von Mises equivalent stress in region B in the improved impeller II is higher than that in region A, with a value of 231MPa. This represents a decrease by 21% compared to the original impeller. That is, the solid impeller greatly reduces the maximum stress. However, a new shaft system needs to be developed to match the solid impeller. When the stress level of the impeller is in the elastic region, speed scaling of elastic results is straight forward. The relationship is that the stress increases with the square of the speed. Thus, the results of the improved designs can be used to extend the maximum speed and then obtain a higher pressure ratio for a specific impeller. On the other hand, it can be used to decrease the cost of an impeller by replacing titanium with aluminum. Titanium has a higher ultimate tensile strength, but it is much more expensive than aluminum. This matters for designers because the cost of the turbocharger is a key factor for commercial market. CONCLUSIONS AND REMARKS In this paper, finite element analysis has been used to model the effects of disk geometric parameters on the strength and deformation of a high pressure ratio centrifugal compressors impeller. For the high pressure ratio centrifugal compressors, high stress will restrict its design and application. The geometric parameters of the impeller disk are important for its stress and deformation. As the results of the investigation the following findings could be established. 4
Fig. 15
The Tip thickness h1 , the rear-disk thickness h 2 and the bore radius
deformation of the impeller. Relatively, the rear-disk height h3 and fillet radius r1 are not important. After finishing the above analysis of effects of geometric parameters of impeller disk, the improved impeller is designed using the improved parameters to reduce the stress. The stress distribution in the improved impellers and that of the original impeller are similar with the same stress concentration regions, but the maximum stress for the improved impellers could be reduced significantly. Comparing to the original impeller, the maximum von Mises equivalent stress of the improved impeller I in region A could be decreased by 19% and the maximum von Mises equivalent stress of the improved impeller II in region A could be decreased by 50%. The improved impeller can bear higher pressure ratios or use cheaper material with lower ultimate tensile strength. ACKNOWLEDGMENTS This research was supported by the National Natural Science Foundation of China (Grant No. 51176087). REFERENCES [1] Zheng X Q, Huenteler J, Yang M Y, et al. Influence of the volute on the flow in a centrifugal compressor of a highpressure ratio turbocharger. Proc. IMechE Part A: Journal of Power and Energy, 2011, 224, pp. 1157-1169. Ricardo M B, Apostolos P, Yang M Y. Overview of boosting options for future downsized engine. Sci China Tech Sci, 2011, 54 (2), pp. 318-331.
[2]
Clenci A C, Descombes G, Podevin P, et al. Some aspects concerning the combination of downsizing with turbocharging, variable compression ratio, and variable intake valve lift. Proc. IMechE Part D: Journal of Automobile Engineering, 2007, 221 (10), pp. 1287-1294. [4] Maiboom A, Tauzia X, Hteta J F. Experimental study of various effects of exhaust gas recirculation (EGR) on combustion and emissions of an automotive direct injection diesel engine. Energy, 2008, 33 (1), pp. 22-34. [5] Zheng X Q, Zhang Y J, Yang M Y, et al. Stability improvement of high-pressure-ratio turbocharger centrifugal compressor by asymmetric flow control part II: non-axisymmetric self recirculation casing treatment. ASME Paper No. GT2010-22582, 2010. [6] Raya G S, Sinhaa B K. Computation of centrifugal stresses in a radial-flow impeller. Comput. Struct., 1991, 40, pp. 731-740. [7] Subramani D A, Ramamurti V, Sridhara K, .Numerical analysis and experimental verification of the radial growth of a turbocharger centrifugal compressor impeller. J. Strain Anal. Eng. Des., 1997, 32, pp. 119-128. [8] Bhope D V, Padole M P. Experimental and theoretical analysis of stresses, noise and flow in centrifugal fan impeller. Mech. Mach. Theory. 2004, 39, pp. 1257-1271. [9] Bonaiuti D, Arnone A, Ermini M, Baldassarre L L. Analysis and optimization of transonic centrifugal compressor impellers using the design of experiments technique. J. Turbomach., 2006, 128, pp. 786-797. [10] Valakos I M, Ntipteni M S, Nikolos I. K. Structural optimization of a centrifugal impeller using differential evolution in CATIA environment. Operational Research, 2007, 7, pp. 185-211.
[3]