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Automotive Engineering_Development of an Advanced Turbocharger Simulation Method for Cycle Simulation of Turbocharged Internal Combustion Engines

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  • 7/28/2019 Automotive Engineering_Development of an Advanced Turbocharger Simulation Method for Cycle Simulation of Tu

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    Development of an advanced turbochargersimulation method for cycle simulation ofturbocharged internal combustion engines

    W Zhuge1, Y Zhang1*, X Zheng1, M Yang1, and Y He2

    1State Key Laboratory of Automotive Safety and Energy, Tsinghua University, Beijing, Peoples Republic of China2R&D and Strategic Planning, General Motors Corporation, MI, USA

    The manuscript was received on 24 July 2008 and was accepted after revision for publication on 4 February 2009.

    DOI: 10.1243/09544070JAUTO975

    Abstract: An advanced turbocharger simulation method for engine cycle simulation wasdeveloped on the basis of the compressor two-zone flow model and the turbine mean-line flowmodel. The method can be used for turbocharger and engine integrated design withoutturbocharger test maps. The sensitivities of the simulation model parameters on turbochargersimulation were analysed to determine the key modelling parameters. The simulation method

    was validated against turbocharger test data. Results show that the methods can predict theturbocharger performance with a good accuracy, less than 5 per cent error in general for boththe compressor and the turbine. In comparison with the map-based extrapolation methodscommonly used in engine cycle simulation tools such as GT-POWERH, the turbochargersimulation method showed significant improvement in predictive accuracy to simulate theturbocharger performance, especially in low-flow and low-operating-speed conditions.

    Keywords: turbocharger, internal combustion engine, cycle simulation

    1 INTRODUCTION

    Turbocharging is playing an increasingly important

    role in developing internal combustion engines for

    today and tomorrow. Turbocharger matching is the

    key technique used to explore optimal solutions for

    minimum fuel consumption and maximum transi-

    ent response together with satisfying all given

    constraints such as maximum turbine temperature,

    turbocharger speed, compressor surge limit, max-

    imum combustion pressure, and knock limit.Engine cycle simulation tools such as GT-POWERH

    are commonly used for turbocharger matching (GT-

    POWER is a registered trademark of Gamma Tech-

    nologies). Compressors and turbines are defined as

    maps within these simulation tools. These maps are

    obtained from test data of available turbochargers.

    Unfortunately, the test data of the turbocharger are

    usually not sufficient for the turbocharger matching

    simulation especially in low-flow and low-speed

    regions. Furthermore, the testing maps of turbines

    are often not available. In this case the turbocharger

    matching has to resort to hands-on testing.

    The map-based turbocharger matching method is

    not efficient. There is a need to develop a model-

    based method to perform turbocharger matching

    without turbocharger testing maps. Compressors

    and turbines are defined with simulation models

    instead of maps within the method. The perfor-

    mance of turbochargers could be changed easily by

    adjusting the model parameters. An optimum match-

    ing between the engine and the virtual turbochar-

    ger could be achieved. The model-based method is

    very useful for integrated engine and turbocharger

    design.

    Although the full three-dimensional (3D) compu-

    tational fluid dynamics simulation is capable of

    predicting the turbocharger performance, it is very

    complicated and time consuming [1, 2]. It is not

    suitable for engine cycle simulation because of itslarge computational footprint. Some researchers

    *Corresponding author: Department of Automotive Engineering,

    Tsinghua University, Tsinghua Park, Haidian District, Beijing,

    100084, Peoples Republic of China.email: [email protected]

    661

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    have developed one-dimensional (1D) semiempirical

    models for compressors and turbines performance

    prediction [38]. These models are commonly used

    for the preliminary design of compressors and turbines

    and can predict the performance well in the design

    conditions. In order to use these models for engine

    cycle simulation, the performance prediction in off-

    design conditions needs to be improved. Winkler

    and Angstrom [9] used the semi-empirical turbine

    model to generate the turbine map for diesel engine

    simulation in transient operation. It was shown that

    the model-generated turbine performance map data

    agree well with the measured map data. However,

    the compressor is still simulated using the test map.

    The present paper develops a numerical method

    to simulate automotive turbochargers in engine

    cycle simulations. The simulation method is based

    on the compressor two-zone flow model and the

    turbine mean-line flow model. The performance

    prediction in off-design conditions is improved. The

    sensitivities of the model parameters on turbochar-

    ger performance simulation were analysed to deter-

    mine the key modelling parameters. The simulation

    method was validated against turbocharger test data.

    2 THE TURBOCHARGER SIMULATION METHOD

    2.1 Compressor model

    The compressor performance prediction is based on

    the analysis of the internal gas flow of the impeller

    using the COMPALH code of Concepts NREC Incor-

    poration [3] (COMPAL is a registered trademark of

    Concepts ETI, Inc.). The impeller flow is modelled

    using the two-zone modelling equations established

    by Japikse [3]. The basic idea of the two-zone model is

    that the impeller exit flow can be conceptually

    divided into a primary zone, which is an isentropic

    core flow region with high velocities, and a secondary

    zone, which is a low-momentum non-isentropic

    region having all the losses occurring in the impeller.

    The primary zone and secondary zone reach static

    pressure balance at the impeller exit. A schematic

    representation of the two-zone model is shown in

    Fig. 1.

    2.1.1 Primary zone equations

    The equations for the primary zone are

    W2p~W1t DR2 1

    h2p~ h1zW21

    2{

    U212

    {

    W22p

    2z

    U222

    2

    P2p

    Tk= k{1 2p

    ~P1

    Tk= k{1 3

    P2p

    T2pr2p~

    P1T1r1 4

    b2p~b2bzd2p 5

    Fig. 1 Schematic representation of the two-zone model

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    where b2b is the exit blade angle, d2p is the exit flow

    deviation angle, the subscript 1 denotes the impeller

    inlet variable, and the subscript 1t denotes the inlet

    tip component.

    The diffusion ratio DR2

    is calculated using the

    correlation

    DR2~ 1{gaCpai

    1{gbCpbi

    {1=26

    where ga and Cpai are the diffusion efficiency and

    ideal diffusion ratio respectively of the segment from

    impeller inlet to throat, and gb and Cpbi are the

    diffusion efficiency and ideal diffusion ratio respec-

    tively of the segment from impeller throat to exit.

    When the impeller flow stalls, DR2 will reach its

    maximum value DRstall. Also

    Cpai~1{1

    AR2a~1{

    cos b1cosb1b

    27

    Cpbi~1{1

    AR2b~1{

    AthA2 cosb2b

    28

    where b1b is the inlet blade angle, Ath is the impeller

    throat area, and A2 is the exit area.

    2.1.2 Secondary zone equations

    The equations for the secondary zone are

    W2s~x _mmtot

    r2seA2 cosb2s9

    h2s~ h1zW21

    2{U21

    {

    W22s2z

    U222

    10

    P2s~P2p 11

    b2s~b2b 12

    where mtot is the total mass flowrate.

    2.1.3 Two-zone mixing equations

    The equations for the two-zone mixing are

    r2mCm2mA2~r2pCm2p 1{e A2zr2sCm2seA2 13

    P2p{P2m

    A2~r2mC2m2mA2{r2pC

    2m2p 1{e A2

    {r2sC22seA2 14

    CpT02a~xCpT02sz 1{x CpT02p 15

    h02m~CpT02azPrecirczPleakzPdf

    _mmtot16

    where T0 is the total temperature, h0 is the total

    enthalpy, Precirc is the recirculation loss, Pleak is the

    leakage loss, and Pdfis the disc friction loss. The Daily

    Nece [10] correlation is used as the disc friction loss

    model. Leakage loss is as modelled by Aungier [6].

    2.1.4 Recirculation loss model

    The recirculation loss is quite important for perfor-

    mance prediction in off-design conditions. Japikse

    [3] established a parabolic correlation between the

    recirculation loss and operating mass flowrate accor-

    ding to

    Precirc~KrecircPEuler 17

    Krecirc~a m{1 2zKrecirc-opt 18

    a~a1, q1

    a2, qw1

    &19

    m~_mm

    _mmopt20

    where PEuler is the Euler power, Krecirc is the

    recirculation loss coefficient, a1 and a2 are correlation

    coefficients, mopt is the optimum mass flowrate, andKrecirc-opt is the recirculation loss coefficient at the

    best efficiency point, which is an empirical constant.

    The Japikse model works well in the design rotating

    speed conditions. In off-design rotating speed condi-

    tions, the prediction error becomes larger since the

    optimum recirculation loss coefficient Krecirc-opt is not

    constant for different rotating speeds. The Japikse

    model is modified for predicting compressor perfor-

    mance better in off-design rotating speed conditions,

    which is important for engine cycle simulations. The

    modified model assumes a parabolic correlation bet-

    ween Krecirc-opt and rotating speeds according to

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    Krecirc-opt~an2zbnzc 21

    n~

    N

    Ndesign 22

    where a, b, and c are correlation coefficients and

    Ndesign is the design rotating speed.

    2.2 Turbine model

    The turbine performance prediction is based on the

    mean-line analysis of the internal gas flow of the turbine

    using the RITALH code of Concepts NREC Incorpora-

    tion [4] (RITAL is a registered trademark of Concepts

    ETI, Inc.). The turbine flow is divided into seven control

    sections. The computation stations are on the boundary

    of these sections. Flow variables are solved at these

    stations, from volute inlet (station 0) to exhaust diffuser

    exit (station 7). The computation stations are shown in

    Fig. 2. For the turbocharger without vaned nozzle and

    diffuser, only the volute and rotor sections are solved.

    The effects of a vaned nozzle as well as the inlet pulsat-

    ing flow condition are not taken into account currently.

    2.2.1 Volute section equations

    The equations for the volute section are

    Ch1~SR0C0

    R123

    Cm1~_mm

    r1A1 1{B1 24

    p01~p00{K p01{p1 25

    where p0 is the total pressure, and the subscripts 0

    and 1 denote the computation stations.

    2.2.2 Rotor section equations

    The equations for the rotor section are

    r6W6A6 cosb6~r4W4A4 cosb4 26

    Cp T04{T06 ~U4Ch4{U6Ch6 27

    T6T06~1{W26

    W26s1{T04

    T06p6p04

    k{1 =k" #28

    W26s{W26~LizLpzLc 29

    where W6s is the isentropic rotor exit relative vel-

    ocity, Li is the incidence loss, Lp is the passage loss,

    and Lc is the tip clearance loss.

    The incidence and passage loss are modelled

    using the NASA models [11, 12] according to

    Li~12

    W24 sin2i 30

    where i5b4b4,opt is the angle between the incoming

    flow and that at the best efficiency point (b4,opt is not

    normally equal to the inlet blade angle, but is usually

    negative)

    Fig. 2 Turbine flow sections

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    Lp~1

    2Kp W

    24 cos

    2 izW26

    31

    where Kp is an empirical loss coefficient.

    The tip clearance loss is modelled using theequation [4]

    Lc~U34ZR

    8pKxexCxzKrerCrzKxr

    ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiexerCxCr

    p 32

    where Kx and Kr are discharge coefficients for the

    axial and radial tip clearance respectively, Kxr is the

    cross-coupling coefficient, and

    Cx~1{R6t=R4

    Cm4b4, Cr~

    R6tR4

    z{b4Cm6R6b6

    33

    2.3 Bearing loss model

    The bearing loss is estimated according to the Petroff

    equation [13]

    LB~KBN

    Ndesign

    234

    where KB is the coefficient determined by the

    turbocharger bearing geometry and lubricant visc-osity.

    The mechanical efficiency of the bearing can be

    deduced from the bearing loss and the isentropic

    efficiency of the turbine, which is obtained from the

    turbine model.

    gmech~1{LB

    Wisgis35

    where Wis is the isentropic turbine work and gis is the

    isentropic turbine efficiency.

    3 SENSITIVITY ANALYSIS OF MODELPARAMETERS

    There are many parameters in the compressor and

    turbine model equations. It will take great effort to

    determine all these parameters accurately for every

    turbocharger simulation. In order to reduce the

    effort of parameter calibration, a sensitivity analysis

    of the turbocharger model parameters on perfor-

    mance prediction is conducted and the key para-

    meters are determined. These key parameters are

    determined by calibration against turbocharger

    experimental test data. A key parameter databasecan be set up for different sizes of turbocharger. The

    database can then be used for the simulation of

    newly designed turbochargers.

    3.1 Compressor key model parameters

    The key parameters of the compressor model are the

    impeller diffusion ratio and the recirculation loss

    coefficient.

    The impeller diffusion ratio DR2 is determined by

    the diffusion efficiencies ga and gb, as well as by thestall diffusion ratio DRstall. The influence ofga on the

    compressor performance prediction is shown in

    Fig. 3. The parameter ga has a significant effect on

    the performance prediction within the range of near-

    design conditions. As ga increases from 0.4 to 0.7, the

    predicted efficiency increases by 3.7 per cent and the

    pressure ratio increases by 5.3 per cent.

    Fig. 3 The influence ofga on the compressor efficiency and pressure ratio prediction

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    The influence of gb on the compressor perfor-

    mance prediction is shown in Fig. 4. The parameter

    gb affects the performance prediction largely within

    the range of high-flow conditions. As gb increases

    from 20.3 to 0.3, the predicted efficiency increases

    by 25.3 per cent and the pressure ratio increases by

    22 per cent.

    The influence of DRstall on the compressor

    performance prediction is shown in Fig. 5. The

    parameter DRstall affects the performance prediction

    largely within the range of low-flow conditions. As

    DRstall increases from 1.09 to 1.29, the predictedefficiency increases by 8.2 per cent and the pressure

    ratio increases by 11 per cent.

    The influence of the recirculation loss coefficient

    Krecirc on the compressor performance prediction

    is shown in Fig. 6. The coefficient has a signific-

    ant effect on the efficiency prediction in off-design

    conditions. The maximum difference between the

    efficiency predictions using variable and fixed co-

    efficients is 17 per cent.

    3.2 Turbine key model parameters

    The key parameters of the turbine model are the

    volute swirl coefficient, the passage loss coefficient,

    the clearance loss coefficients, and the rotor exit flow

    deviation angle.

    The influence of the volute swirl coefficient S on

    the turbine performance prediction is shown in

    Fig. 7. The coefficient has a significant effect on boththe turbine throughput and efficiency predictions.

    As the coefficient increases from 0.75 to 0.90, the

    predicted pressure ratio increases by 6 per cent and

    the efficiency increases by 3.6 per cent.

    The influence of the passage loss coefficient Kp on

    the turbine performance prediction is shown in Fig. 8.

    The coefficient affects largely the turbine efficiency

    Fig. 4 The influence ofgb on the compressor efficiency and pressure ratio prediction

    Fig. 5 The influence of DRstall on the compressor efficiency and pressure ratio prediction

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    prediction. As the coefficient increases from 0.15 to

    0.35, the predicted pressure ratio increases by 4.2 per

    cent and the efficiency decreases by 8.4 per cent.

    The influences of the clearance loss coefficients Kx

    and Kr on the turbine performance prediction areshown in Fig. 9. The coefficients affect largely the

    turbine efficiency prediction. As the coefficients

    increase from 0.5 to 3, the predicted pressure ratio

    increases by 3.3 per cent and the efficiency decreases

    by 7.9 per cent.

    The influence of the deviation angled

    on the turbineperformance prediction is shown in Fig. 10. The

    Fig. 6 The influence of Krecirc on the compressor efficiency and pressure ratio prediction

    Fig. 7 The influence of S on the turbine throughput and efficiency prediction

    Fig. 8 The influence of Kp on the turbine throughput and efficiency prediction

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    predicted turbine throughput is largely affected by this

    coefficient. As the deviation angle increases from 0u to

    3u, the predicted pressure ratio decreases by 3.2 per

    cent and the efficiency increases by 1.5 per cent.

    4 VALIDATION OF THE SIMULATION METHOD

    4.1 Turbocharger geometry measurement

    The turbocharger simulation method is validated

    against turbocharger test data. The geometry para-

    meters of the turbocharger are obtained by scanning

    the compressor and turbine impeller using optical

    digitizing sensors and a three-coordinate measuring

    machine. The created computer-aided design (CAD)

    models of the compressor and turbine are shown in

    Fig. 11.

    4.2 Results of validation

    The key parameters of turbocharger models are

    calibrated using only some of the available turbo-

    charger testing data. The calibrated models are val-idated against the additional experimental data. The

    turbocharger test is conducted at General Motors.

    The turbocharger is powered by compressed air hea-

    ted to 600 uC on the test rig. The turbine power is

    derived by the calculation of the compressor power.

    4.2.1 Validation of the compressor simulationmethod

    Three sets of compressor test data (140 000 r/min,

    120 000 r/min, and 100 000 r/min) are used to cali-

    brate the compressor model key parameters. Thevalues of the key modelling parameters are listed

    Fig. 9 The influences of Kx and Kr on the turbine throughput and efficiency prediction

    Fig. 10 The influence ofd on the turbine throughput and efficiency prediction

    Fig. 11 Compressor and turbine CAD models

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    in Table 1. The calibrated model is used for predict-

    ing the turbocharger performance at 80 000 r/min.

    Figure 12 shows the validation results. The solid

    curves represent the prediction results and the

    symbols represent the experimental data points.

    Figure 12 shows that the predicted performance

    curve agrees well with the experimental data points.

    The maximum error of the pressure ratio prediction

    error is 5.1 per cent. The maximum error of the

    efficiency prediction is less than 5 per cent for most

    points except for high-flow (near-choking) points.

    Since the compressor is rarely operated in near-

    choking conditions for a real engine, because of the

    very low efficiency of the compressor operating in

    these conditions, the prediction inaccuracy at near-

    choking points is not very important. Therefore the

    developed simulation method is accurate enough for

    simulating compressor characteristics in engine

    cycle simulations.

    4.2.2 Validation of the turbine simulation method

    Three sets of turbine test data (147750 r/min,

    132970 r/min, and 118 220 r/min) are used to cali-

    brate the turbine model key parameters. The values

    of the key modelling parameters are listed in Table 2.

    The calibrated model is used for predicting the

    turbocharger performance at 103 420 r/min, 88 670 r/

    min, and 73 860 r/min. Figure 13 shows the valida-

    tion results. The solid curves represent the predic-

    tion results and the symbols represent the experi-

    mental data points.

    Figure 13 shows that the predicted performance

    curve agrees well with the experimental data points.

    The maximum error of the pressure ratio prediction

    error is 2.9 per cent. The maximum error of the

    efficiency prediction is less than 5 per cent in most

    points except for one point at the lowest operating

    speed, the value for which is 6.2 per cent. The

    developed simulation method is accurate enough for

    simulating turbine characteristics in engine cycle

    simulations.

    4.3 Performance prediction with the GT-POWERextrapolation methods

    The turbocharger test performance data for modelcalibration (three sets of test data) are input into GT-

    POWER to generate the turbocharger performance

    maps. The performance of the turbocharger in the

    conditions of the model validation is predicted using

    the GT-POWER map extrapolation method.

    Figure 14 shows the validation results for the

    compressor performance prediction by GT-POWER.

    The solid curves represent the prediction results and

    the symbols represent the experimental data points.

    Table 1 Values of the key modellingparameters of the compressor

    Parameter Value

    ga 0.55gb 20.1

    DRstall 1.19a1 0.75a2 0.125a 0.81b 21.54c 0.745

    Fig. 12 Comparison of the predicted compressor pressure ratio and efficiency with validationdata

    Table 2 Values of the key modellingparameters of the turbine

    Parameter Value

    S 0.82Kp 0.25

    Kx 2Kr 2d 3uKB 1200

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    In comparison with Fig. 12, the pressure ratio

    prediction by GT-POWER is a little better than the

    compressor simulation method but the efficiency

    prediction is worse than the simulation method for

    most points at 80 000 r/min. However, the efficiency

    prediction in the near-choking condition by GT-

    POWER is much better.

    GT-POWER uses power curves to fit the input data

    for the turbine. The equation used to calculate the

    mass flow is

    MR~Cmz 1{Cm BSRm 36

    where MR is the mass flow ratio, which is the ratio of

    the mass flow to the mass flow at the maximum

    efficiency point, Cm is a coefficient, BSR is the

    normalized blade speed ratio with respect to the

    blade speed ratio at the maximum-efficiency point,

    and m is the mass flow ratio exponent.

    The equation for the efficiency curve at low BSR

    (BSR,1) is

    g~1{ 1{BSR b 37

    where b is the efficiency curve shape factor at low

    BSRs. The efficiency curve at high BSRs (BSR.1) is a

    parabola drawn through the maximum-efficiency

    point and the point at efficiency intercept at high

    BSR (BSRi).

    The values of the coefficients that determined the

    shape of the fitting curves can be adjusted to fit the

    data best. These coefficients are tuned using the test

    data and are listed in Table 3.

    Figure 15 shows the validation results for the

    turbine performance prediction by GT-POWER.The solid curves represent the prediction results

    and the symbols represent the experimental data

    points. In comparison with Fig. 13, both the pressure

    ratio prediction and the efficiency prediction by GT-

    POWER are worse than the predictions by the

    Fig. 13 Comparison of the predicted pressure turbine ratio and efficiency with validation data

    Fig. 14 Comparison of the predicted compressor pressure ratio and efficiency by GT-POWER

    with validation data

    Table 3 Coefficients for the turbine data fitting

    Coefficient Value

    Cm 1.05m 2b 1.5

    BSRi 2

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    turbine simulation method. The maximum predic-

    tion error of the efficiency prediction by GT-POWER

    is 13 per cent.

    5 CONCLUSIONS

    A turbocharger simulation method for engine cycle

    simulations was developed on the basis of the

    compressor two-zone model and the turbine

    mean-line flow model. The recirculation loss model

    was improved for predicting the compressor perfor-

    mance better in off-design conditions. The sensi-

    tivities of the model parameters on turbocharger

    simulation were analysed. The key modelling para-

    meters were determined. For the compressor model,

    the impeller diffusion ratio coefficients and the

    recirculation loss coefficients are the key para-

    meters. For the turbine model, the volute swirl

    coefficient, the passage loss coefficient, the clear-

    ance loss coefficients, and the rotor exit flow

    deviation angle are the key parameters.

    The models are calibrated using only a some of the

    available turbocharger testing data, and the cali-

    brated models were validated against the remaining

    test data to evaluate the general predictive accuracy.

    The results of the validation of the turbocharger

    simulation methods against test data show that the

    methods can predict the turbocharger performance

    at a good accuracy, less than 5 per cent error in

    general for both the compressor and the turbine. The

    efficiency prediction in near-choking conditions of

    the compressor needs to be improved.

    In comparison with the conventional map-based

    extrapolation approach commonly used in engine

    cycle simulation tools such as GT-POWER, the tur-

    bocharger simulation methods developed in this

    study showed significant improvement in predictiveaccuracy to simulate the turbocharger performance,

    especially in low-flow and low-operating-speed con-

    ditions.

    ACKNOWLEDGEMENTS

    The authors would like to thank General Motors fortheir support. This work is also supported by theNational Natural Science Foundation of China (Project50706020) and the Open Research Fund Program ofthe National Key Laboratory of Diesel Engine Tur-bocharging Technology (Project 9140C3311010804).

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    Fig. 15 Comparison of the predicted turbine pressure ratio and efficiency by GT-POWER withvalidation data

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    APPENDIX

    Notation

    A area (m2)

    AR area ratio

    b blade heightB blocking coefficient

    Cm absolute meridional velocity (m/s)

    Cp specific heat (J/kg K)

    Cpai, Cpbi ideal diffusion ratio

    Ch absolute tangential velocity (m/s)

    DRstall diffusion ratio when the compressor

    impeller flow stalls

    DR2 diffusion ratio of the compressor

    rotor

    h specific enthalpy

    i incidence angle

    K empirical loss coefficient

    Krecirc recirculation loss coefficient

    L energy lossm mass flowrate (kg/s)

    N turbocharger operating speed

    (r/min)

    P pressure (Pa)

    R radius

    S swirl coefficient

    T temperature (K)

    U circumferential velocity (m/s)

    W relative velocity (m/s)

    z turbine rotor axial length

    ZR blade number

    b flow angle or blade setting angle

    d deviation angle

    e secondary zone area fraction

    er radial tip clearance (m)

    ex axial clearance (m)

    g efficiency

    ga, gb diffusion efficiencies

    r density (kg/m3)

    x secondary mass flow fraction

    Subscripts

    2s compressor exit secondary zone

    variables

    2p compressor exit primary zone

    variables

    2m compressor exit mixing flow

    variables

    s isentropic process

    672 W Zhuge, Y Zhang, X Zheng, M Yang, and Y He

  • 7/28/2019 Automotive Engineering_Development of an Advanced Turbocharger Simulation Method for Cycle Simulation of Tu

    13/13

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