CFD Meshing to Turbocharger Model

TURBO CHARGER:

A turbocharger, cooloquially known as a turbo, is a turine-driven forced induction device that increases an intenal combustion engine's efficiency and power outut by focing extra compressed air into the combustion chamber. Turbocharger performance influences all important engine paameter, such as fuel economy, power, and emissions.

A turbocharger consists of a compressor wheel and exhaust gas turbine wheel coupled together by a solid shaft and that is used to boost the intake air pressure of an internal combustion engine. The exhaust gas turbine extracts energy from the exhaust gas and uses it to drive the compressor and overcome friction.

In most automotive-type applications, both the compressor and turbine wheel are of the radial flow type. Some applications, such as medium- and low- speed diesel engines, can use an axial flow turbine wheel instead of a radial flow turbine. 

[schematic]

Objective:

To clear all the topologial errors and mesh the given turbochargermodel using ANSA.

Procedure:

# Import the turbocharger model into ANSA. Turn onthe shadow mode and convert into PID mode. open qulality criteria and go to presentation parameters tab then click on the check box Drawcons in PID, MID.. mode like in ENT mode in Visualization mode.

Steps to follow:

1. Clearing Topological errors.

2. Assiging PID's to various components.

3. Making surface mesh.

4. Making Volumetric mesh.

1. Clearing Topological errors:

# check for topological errors for the given model through geometry check up in the utility window or turn off the shadow mode to see single cons and triple cons.

# Use NOT, Universal delete, coons, fitted, Hot points (for splitting the surfaces0 , PROJECT, INTERSECT commands to clear all topological errors.

NOT- to hide the surface fo proper viewing of the error.

Delete- to delete he overlapping surfaces.

Coons- to define a new surface by its boundary curves.

Fitted- to create a surface that fits between the selected boundaries.

Hot points- To split the con.

Project- to project the cons on the selected surface.

Intesect- to intersect the surfaces.

# Make a geemetric check to make sure every topologiacal error os removed.

# Make blade stage1, stage2, Impeller, shaft rotor to a common volume by using TOPO, PROJECT, DELETE commands.

# also remove the intersections in the surfaces.

2. Assiging PID's to various Components:

# Assign PID to every surface as per each component in properties tab, so that for assiging or selecting certain componentis easy to access.

 

# compress the unwanted PIDsusing compress command. this makes undelete option no longer useful.

3. Making Surface Mesh:

# Switch to MESH mode from TOPO.

# Assign element sizeof each component as follows: 

- Blade stage1- 1mm
- Blade stage2- 1mm
- Compressor casing- 5mm
- Impeller- 2mm
- Inlet casing cover- 5mm
- Shaft rotor- 1mm
- Turbo casing- 5mm.

# Mesh the entire turbocharger by MESHGENERATION  function.

# in close observation we came to know that, at component change ove time meshung doesn't happen uniformly since element size for each component varied.

# make a patch at the joints using MARK/UN Option for an element size of 3mm so that mesh size won't decrease gradually.

4. Making Volumetric mesh:

# Switch to V.Mesh mode in the Utility window. 

# Goto DEFINE tab in VOLUMES to get available volumes.

# Keep the volumes needed and delete the rest.

# create a volumetric mesh for the needed by using unstructured Mesh- TETRA CFD

Conclusion: 

Surface and volumetric mesh for given Turbocharger modelis done by cleaning all topological errors.

Observations and learnings:

# Usage of Universal DELETE, UNDELETE, New faces, COONS, FITTED, TOPO, HOTPOINTS, CUT, INTERSECT options.

# Volumetric meshing procedure.

#Element size based surface meshung and elimination of abrupt meshing.

 

https://drive.google.com/file/d/140SVquJOPxq7taldzD5WVUBZcElqrnTa/view?usp=sharing

 


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