Design Of Automotive Parts For 5 Axis Milling Machine.
DESIGN OF AUTOMOTIVE PARTS FOR
5 AXIS MILLING MACHINE
KUAH CHUEN TSE
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Design of Automotive Parts For
5 Axis Milling Machine
Thesis submitted in accordance with the partial requirements of the
Universiti Teknikal Malaysia Melaka for the
Bachelor of Manufacturing Engineering (Manufacturing Process)
By
Kuah Chuen Tse
Faculty of Manufacturing Engineering
May 2008
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS TESIS*
JUDUL: _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ SESI PENGAJIAN : _______________________
Saya _____________________________________________________________________
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Tesis adal ah hak milik Universit i Teknikal Malaysia Mel aka .
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat sal inan unt uk t uj uan pengaj ian sahaj a.
3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.
4. **Sil a t andakan (√)
(HURUF BESAR)
SULIT TERHAD TIDAK TERHAD
(Mengandungi makl umat yang berdarj ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)
(TANDATANGAN PENULIS) Alamat Tet ap:
Tarikh: _______________________
Disahkan oleh:
(TANDATANGAN PENYELIA) Cop Rasmi:
Tarikh: _______________________
* Tesis dimaksudkan sebagai t esis bagi Ij azah Dokt or Fal saf ah dan Sarj ana secara penyel idikan, at au disert asi bagi pengaj ian secara kerj a kursus dan penyel idikan, at au Laporan Proj ek Sarj ana Muda (PSM). ** Jika t esis ini SULIT at au TERHAD, sil a l ampirkan surat daripada pihak berkuasa/ organisasi berkenaan
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DECLARATION
I hereby, declared this thesis entitled “Design of Automotive Parts For 5 Axis Milling Machine” is the results of my own research
except as cited in references.
Signature : ……….
Author’s Name : ………
Date : ………
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ABSTRACT
Turbocharger is one of the approaches that utilize the exhaust gas of an automobile to drive the compression device. The purpose of turbocharging is to increase the intake pressure and the amount of air into the combustion chamber to improve the efficiency of the engine. One of the main problems with turbochargers is that they do not provide an immediate power boost when the accelerator pad is pressed, and the car would accelerate forward suddenly when the turbocharger gets moving. This study investigated how the design of a turbocharger’s turbine-compressor assembly affects the efficiency of a turbocharger and improved the design of the turbine-compressor assembly in term of transient response. Computational Fluid Dynamics (CFD) program is used to simulate fluid flow of the design. And rapid prototype machine is used to make a prototype of the turbine-compressor assembly. The major contribution of this project is the design concept that can be implemented to other turbocharger to reduce the effect of turbo-lag and improve the transient response of a turbocharger.
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ABSTRAK
Turbocharger merupakan sejenis kaedah menggunakan gas ekzos dalam sesebuah
kenderaan untuk menjalankan unit pemampat. Tujuan menggunakan turbocharger
adalah untuk meningkatkan tekanan udara dan kuantiti udara yang memasuki ke dalam enjin supaya meningkatkan kecekapan enjin. Satu masalah yang terdapat pada
turbocharger ialah ia tidak membekalkan boost dengan serta-merta dan kenderaan
akan memecut secara tiba-tiba apabila turbocharger mula bergerak. Projek ini menyelidikkan kesan rekabentuk turbine dan compressor sesebuah turbocharger
terhadap kecekapannya. Rekabentuk turbine dan compressor baru akan dicadangkan untuk menggurangkan kesan turbo-lag. Atur cara komputer dinamik bendalir (CFD) digunakan untuk mengkaji pengaliran gas dalam turbocharger tersebut. Prototaip Pesat (RP) mesin digunakan untuk membuat satu prototaip rekabentuk ini. Sumbangan utama projek ini adalah konsep rekabentuk yang boleh digunakan untuk turbocharger yang lain untuk mengurangkan kesan turbo-lag dan meningkatkan kecekapan sesebuah turbocharger.
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DEDICATION
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ACKNOWLEDGEMENTS
This research was performed under the supervision of Mr. Taufik, whom I would like to thank for the freedom granted in carrying out this project. I also would like to express my deep appreciation for Mr. Taufik understanding regarding the difficulties I had during the project.
I would like to gratefully acknowledge Mr. Shahrul for his consultation on the CNC machining. I would like to express my appreciation to Mr. Halim and Prof. Md. Dan for being my panels and that they spend time to evaluate my report.
A special thank to my friend, Mr. Jia Chang, for his help on the ANSYS simulation. And to all my friends who we have worked together for our projects, I could not achieve it without their support and encouragement.
Most of all, I would like to thank my parents, for their patience and support all the years, I appreciate the sacrifices they have made for me.
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TABLE OF CONTENTS
ABSTRACT ... i
ABSTRAK ... ii
DEDICATION... iii
ACKNOWLEDGEMENTS... iv
TABLE OF CONTENTS...v
LIST OF TABLES... viii
LIST OF FIGURES ... ix
LIST OF ABBREVIATIONS AND SPECIALIZED NOMENCLATURE ... xi
LIST OF APPENDICES... xii
CHAPTER 1 INTRODUCTION ...1
1.1 Background of Study ... 1
1.2 Problem Statement ... 2
1.3 Objective of PSM... 3
1.4 Scope of Work ... 3
1.5 Schematic of Project ... 4
1.6 Gantt Chart... 5
CHAPTER 2 LITERATURE REVIEW ...6
2.1 Introduction... 6
2.2 Turbocharger and Turbocharging Techniques... 6
2.3 Turbocharger Lag ... 10
2.4 Proposed Solutions to Reduce Turbocharger Lag ... 12
2.4.1 Hydraulic Assist System... 14
2.4.2 Air-injection system... 14
2.4.3 Hybrid turbocharging... 15
2.4.4 Variable Geometry Turbines (VGT)... 17
2.4.5 Sequential Turbocharging... 19
2.4.6 Power Assist Systems ... 21
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2.5 Dynamics of Turbocharger ... 29
2.6 5 Axis CNC Milling Machine... 29
2.7 CAD/CAM... 30
2.8 ANSYS CFX... 31
CHAPTER 3 MATERIALS AND METHODOLOGY...33
3.1 Introduction... 33
3.2 Methodology... 34
3.2.1 Phase 1: Conceptual and Planning... 35
3.2.2 Phase 2: Design and Analysis ... 35
3.2.3 Phase 3: Machining... 36
3.2.4 Phase 4: Discussion and Conclusion ... 36
3.3 Material, Hardware and Software Requirement ... 36
3.4 Work Planning ... 37
3.5 Method to Conduct an ANSYS simulation... 39
3.5.1 Step 1 – Pre-Processor: Geometry Creation ... 39
3.5.2 Step 2 – Pre-Processor: CFX Meshing ... 39
3.5.3 Step 3 – Pre-Processor: Physics Preprocessor ... 40
3.5.4 Step 4 – Simulation in ANSYS Solver ... 41
3.5.5 Step 5 – Post-Processing: Viewing the Results ... 41
CHAPTER 4 RESULTS ...42
4.1 Introduction... 42
4.2 Technical Drawings ... 42
4.2.1 Design 1 ... 43
4.2.2 Design 2 ... 47
4.3 Mass and Inertia Reports of Design ... 51
4.3.1 Design 1 ... 51
4.3.2 Design 2 ... 52
4.4 Simulation Results ... 53
CHAPTER 5 DISCUSSION...58
5.1 Discussion on the Design... 58
5.1.1 Reduction in Volume and Masses ... 59
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5.2 Design Selection ... 60
5.3 Material Selection ... 61
5.4 Discussion on the Simulation ... 62
5.4.1 The Simulation and Its Limitation ... 62
5.4.2 Air Flow Path and Changes in Temperature... 63
5.4.3 Pressure Boost Obtained ... 64
CHAPTER 6 CONCLUSION...65
REFERENCES ...66
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LIST OF TABLES
Table 2-1: Summary of the Comparison Results for the First Gear Acceleration 24 Table 2-2: Summary of the Comparison Results for the Third Gear Acceleration 24 Table 3-1: Hardware and Software Requirement 36 Table 3-2: Work Breakdown Structure of Project 37
Table 4-1: Summary of Simulation 57
Table 5-1: Comparison between Design 1 and 2 60
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LIST OF FIGURES
Figure 1-1: Gantt Chart of PSM 1 5
Figure 1-2: Gantt Chart of PSM 2 5
Figure 2-1: Inlet and Exhaust Gas Flow Through a Turbocharger 7 Figure 2-2: The Effect of Turbine and Compressor Wheel Size on Acceleration
Response Time to Reach Designed Maximum Boost Pressure 11 Figure 2-3: A Schematic of a Hyperbrid Supercharging System 16
Figure 2-4: VGT Turbocharger 17
Figure 2-5: Engine Speed, Vehicle Speed, Inlet Manifold Pressure and Fuel Injected Histories during Full Power Acceleration From 0 to 60 mph. Results Obtained by Comparing the Conventional and the VGT Turbocharger 18 Figure 2-6: BMW 535D Turbocharger System Concept 20 Figure 2-7: Twin Turbo Parallel Configuration 20 Figure 2-8: Diesel Engine with an Electric Motor in a Parallel Hybrid Configuration, where Pem Denotes the Supplemental Power 22
Figure 2-9: Diesel Engine with a Turbocharger Power Assist System, where Pem
Denotes the Supplemental Power 23
Figure 2-10: Comparison of Torque Characteristics and Acceleration Response With
and Without TPAS 23
Figure 2-11: Comparison of Compressor Acceleration Speeds for Different Levels of
Assist Power 25
Figure 2-12: Types of Mechanical Supercharger: (a) Rotating Lobe (b) Sliding Vane (c) Rotating Impeller (d) Orbiting Spiral 27
Figure 2-13: CFD Design Iteration 32
Figure 3-1: Flow Chart of the Project 34
Figure 3-2: ANSYS CFX Flow chart 39
Figure 4-1: Compressor Design 1 43
Figure 4-2: Compressor Design 1 44
Figure 4-3: Turbine and Shaft Design 1 45 Figure 4-4: Turbine-Compressor Assembly Design 1 46
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Figure 4-5: Compressor Design 2 47
Figure 4-6: Compressor Design 2 48
Figure 4-7: Turbine and shaft Design 2 49 Figure 4-8: Turbine-Compressor Assembly Design 2 50 Figure 4-9: (A) Geometry imported into ANSYS Modeler; 53
Figure 4-10: Flow path streamline 1 54
Figure 4-11: Detailed temperature streamline profile at compressor side. 55
Figure 4-12: Simulation Summary 57
Figure 5-1: Bottom of compressor 58
Figure 5-2 Temperature change at the compressor side. (A) Top view; (B) 3D view; (C) Back view; and (D) Front view. 63
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LIST OF ABBREVIATIONS AND SPECIALIZED
NOMENCLATURE
CAD - Computer-aided Design
CAD/CAM - Computer-aided Design and Computer-aided Manufacturing CAE - Computer-aided Engineering
CAM - Computer-aided Manufacturing
CATIA - Computer Aided Three Dimensional Interactive Application CFD - Computational Fluid Dynamics
CFX - Advanced Computational Fluid Dynamics CNC - Computer Numerical Control
ECU - Engine Control Unit FEA - Finite Element Analysis MRR - Material Removal Rate NA - Naturally Aspirated
PLM - Product Lifecycle Management TPAS - Turbocharger Power Assist System VGT - Variable Geometry Turbine
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LIST OF APPENDICES
Figure A: Housing Model 69
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CHAPTER 1
INTRODUCTION
1.1
Background of Study
Automobile has become the most common and most important mean of personal transportation. Millions of people around the world depend on their vehicle to travel here and there. The origin of the automobile can be traced to Europe. It was not common for people to own a car by then due to cars was so expensive. After a century of the automobile, today, more and more people own cars.
Engine is sometimes described as the heart of an automobile. Engine is where the burning of a mixture of fuel and air takes place and it produces mechanical energy to drive the automobile. However, engine cannot work by itself; it has to work together with other automotive parts, for instant, the manifold system. While new engines are not redesigned very frequent, it has the necessity to undertake major redesign of the manifold systems on a more regular basis, as mentioned by Winterbone and Pearson (1999) in their studies.
Winterbone and Pearson (1999) explained how the intake and exhaust manifolds affect engine performance, as well as emissions of noise and pollutants. The potential for energy release in the combustion process, which is manifested as the indicated mean effective pressure or the torque generated, is related to the amount of air entering the cylinders. The majority of engines used in automobile applications is naturally aspirated and operate on the four-stroke cycle, in which distinct strokes of the piston are used to induce the air and exhaust it. There are also other means to introduce the air into the cylinders. The most common methods are
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supercharging, which uses a prime mover to drive the compression device; and turbocharging, a method which utilize the exhaust gas to drive the compression device. These methods are having the same objective that is to increase the intake pressure and the amount of air into the combustion chamber; thus improving the efficiency of the engine. Generally speaking, a turbocharger is more efficient than a centrifugal supercharger. The scope of this study will be limited on the turbocharging method only.
This study will investigate how the design of a turbocharger’s turbine-compressor assembly affects the efficiency of a turbocharger and will try to improve the design of the turbine-compressor assembly. Furthermore, finite element analysis will be done on the redesigned models of the assembly to validate the designs. This study also included machining the prototype of turbine and compressor. 5-axis CNC machining will be used for the machining of the parts.
1.2
Problem Statement
One of the main problems with turbochargers is that they do not provide an immediate power boost when the accelerator pad is pressed, and the car accelerate forward suddenly when the turbo gets moving. Usually a delay is produced between pressing on the accelerator pedal and the boost. This is due to the loss of energy to overcome the rotational inertia of the turbine rotor. This problem is usually described as turbo-lag (Nice, n.d.).
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1.3
Objective of PSM
The aims of this project are to:
(a) Study and improve the design of a turbocharger turbine-compressor assembly.
(b) Fabricate a prototype of the design using 5 axis CNC machine.
1.4
Scope of Work
The automotive part chosen for this project is the turbine-compressor assembly inside a turbocharger. The purpose of this project is to study and improve the design of the turbine-compressor assembly. The main focus is on the turbo-lag. The cause of Turbo-lag will be studied and improved in the project.
In addition, a prototype of the model will be fabricated by using 5-axis CNC machining. Before the real machining takes place, machining simulation will be performed using CATIA; and the NC code will be generated. The parameters, for instance, feed, speed, and material removal rate (MRR) involved in the machining will be recorded as well.
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1.5
Schematic of Project
Chapter 1 describes about the background of the study, project problem statement, and the objective and scope of the study.
Chapter 2 highlighted some literature reviews related to the study, which includes descriptions on turbocharger, turbo-lag, proposed technical solutions for turbo-lag, CNC machining, CAD/CAM, and ANSYS CFX.
Chapter 3 shows the methodology and the flow of this project in detail from the beginning.
Chapter 4 includes the result of the analysis and the presentation of data.
Chapter 5 provides a general discussion on the design, the results of the study, stressing the significance and implications of the findings of the study.
Chapter 6 makes a conclusion on the study. Suggestions for future study are included in this section as well.
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1.6
Gantt Chart
Gantt chart has been built to give a visual presentation of the schedule of the project flow. It shows the general sequence of project activities. Gantt chart is as well a very useful tool to assist in tracking and monitoring the project progress. Figure 1-1 and Figure 1-2 below are the Gantt charts of the PSM 1 and PSM 2.
Figure 1-1: Gantt Chart of PSM 1
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CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
This section highlights some literature reviews related to the study. Firstly, an overview of turbocharger, its significance, and its applications are presented. Secondly, turbo-lag and its proposed technical solutions are being highlighted. Finally, reviews of CAD/CAM and ANSYS CFX are presented.
2.2
Turbocharger and Turbocharging Techniques
Turbochargers are a type of forced induction system that compresses the air flowing into the engine. Compressing the air introduces more air into the engine, and more air means that more fuel can be added. Thus, more power can be provided by the combustion process and in other word, the efficiency or power-to-weight ratio for the engine is improved. The flow of gas through a turbocharger is shown in Figure 2.1.
The turbocharger itself is rather a simple device; the typical turbocharger consisting a single turbine attached by a shaft to a single compressor. The operation of a turbocharger is explained in detail by Aaron Joseph King (2002) in his research. The turbine is driven by the exhaust gas at high temperature and pressure from the exhaust manifold. The work of the turbine drives the compressor, and the air entering the intake manifold is compressed. Although this arrangement seems simple, due to
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quite complex. Despite the complications of transient operation of an engine, the advantages associated with the implementation of a turbocharger are universally accepted when applied to high efficiency diesel engines. Significant effort has been aimed at improving the efficiency and power to weight advantages of turbocharged engines.
Figure 2-1: Inlet and Exhaust Gas Flow Through a Turbocharger
Source: Nunney (2006)
Early turbocharging systems isolate the turbine from the inherently unsteady exhaust flow by connecting a large exhaust plenum between the exhaust valves and turbine. The plenum served to dampen the transient exhaust pulsations, allowing the turbocharger to operate in an essentially steady pressure environment. This technique is called constant pressure turbocharging. Due to the isenthalpic expansion process, constant pressure turbocharging decreases available energy to the turbocharger. It also results in a system of high volumetric capacitance, which degrades the system response time to engine accelerations and decelerations.
Therefore, in an effort to utilize more of the energy available from the exhaust flow, a technique known as pulse turbocharging has been developed and become the dominant technology. Pulse turbocharging minimizes the expansion losses by attaching the turbocharger to a small exhaust manifold, subjecting the turbocharger to the full transient of the discrete exhaust valve events. The net loss is
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less than that which occurs in the larger manifolds of a constant-pressure system, but, as a trade-off, the efficiency of the turbocharger subjected to pulsating flow is typically lower. A detailed description of pulse turbocharging has been given by Heywood (1998).
Turbochargers increase the efficiency and performance of diesel engines by extracting more power out of a given engine. Recycling energy from exhaust gases, turbochargers use that gas to turn a turbine, which in turn spins an air pump, which subsequently forces compressed air into the engine’s cylinders. Without a turbocharger, a diesel engine does not accelerate as fast as a gasoline engine. However, a turbocharged diesel overcomes this by forcing more air into the engine.
Honeywell estimates the “turbo effect” of adding a turbocharger to a regular diesel engine to be 70% additional fuel economy. According to a marketing research of Gabelli & Company, Inc. in 2004, the global turbocharger market is approximately 15 million units. Turbochargers are sold, on average, for about $200 each. According to the researcher of the report, David (2004), Turbochargers in the personal vehicle market represent a significant opportunity for the turbocharger or turbocharged engine manufacturers and companies.
Thus, due to the market opportunities of turbochargers, continuous efforts have been made to improve efficiency and matching of rotary machines with internal combustion engine over the widest possible range of operating conditions.
Ceausu (2006) mentioned that the typical boost provided by a turbocharger is 6 to 8 psi. Since normal atmospheric pressure is 14.7 psi at sea level, turbocharger is getting about 50 percent more air into the engine. Therefore, 50 percent more power is expected to obtained. However, nothing is perfectly efficient, so a 30- to 40-percent improvement might be obtained instead.
The turbocharged direct injected diesel engine has become an attractive alternative to gasoline engines on vehicle market. From the evolution of diesel
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1.3
Objective of PSM
The aims of this project are to:
(a) Study and improve the design of a turbocharger turbine-compressor assembly.
(b) Fabricate a prototype of the design using 5 axis CNC machine.
1.4
Scope of Work
The automotive part chosen for this project is the turbine-compressor assembly inside a turbocharger. The purpose of this project is to study and improve the design of the turbine-compressor assembly. The main focus is on the turbo-lag. The cause of Turbo-lag will be studied and improved in the project.
In addition, a prototype of the model will be fabricated by using 5-axis CNC machining. Before the real machining takes place, machining simulation will be performed using CATIA; and the NC code will be generated. The parameters, for instance, feed, speed, and material removal rate (MRR) involved in the machining will be recorded as well.
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1.5
Schematic of Project
Chapter 1 describes about the background of the study, project problem statement, and the objective and scope of the study.
Chapter 2 highlighted some literature reviews related to the study, which includes descriptions on turbocharger, turbo-lag, proposed technical solutions for turbo-lag, CNC machining, CAD/CAM, and ANSYS CFX.
Chapter 3 shows the methodology and the flow of this project in detail from the beginning.
Chapter 4 includes the result of the analysis and the presentation of data.
Chapter 5 provides a general discussion on the design, the results of the study, stressing the significance and implications of the findings of the study.
Chapter 6 makes a conclusion on the study. Suggestions for future study are included in this section as well.
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5
1.6
Gantt Chart
Gantt chart has been built to give a visual presentation of the schedule of the project flow. It shows the general sequence of project activities. Gantt chart is as well a very useful tool to assist in tracking and monitoring the project progress. Figure 1-1 and Figure 1-2 below are the Gantt charts of the PSM 1 and PSM 2.
Figure 1-1: Gantt Chart of PSM 1
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CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
This section highlights some literature reviews related to the study. Firstly, an overview of turbocharger, its significance, and its applications are presented. Secondly, turbo-lag and its proposed technical solutions are being highlighted. Finally, reviews of CAD/CAM and ANSYS CFX are presented.
2.2
Turbocharger and Turbocharging Techniques
Turbochargers are a type of forced induction system that compresses the air flowing into the engine. Compressing the air introduces more air into the engine, and more air means that more fuel can be added. Thus, more power can be provided by the combustion process and in other word, the efficiency or power-to-weight ratio for the engine is improved. The flow of gas through a turbocharger is shown in Figure 2.1.
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7
quite complex. Despite the complications of transient operation of an engine, the advantages associated with the implementation of a turbocharger are universally accepted when applied to high efficiency diesel engines. Significant effort has been aimed at improving the efficiency and power to weight advantages of turbocharged engines.
Figure 2-1: Inlet and Exhaust Gas Flow Through a Turbocharger
Source: Nunney (2006)
Early turbocharging systems isolate the turbine from the inherently unsteady exhaust flow by connecting a large exhaust plenum between the exhaust valves and turbine. The plenum served to dampen the transient exhaust pulsations, allowing the turbocharger to operate in an essentially steady pressure environment. This technique is called constant pressure turbocharging. Due to the isenthalpic expansion process, constant pressure turbocharging decreases available energy to the turbocharger. It also results in a system of high volumetric capacitance, which degrades the system response time to engine accelerations and decelerations.
Therefore, in an effort to utilize more of the energy available from the exhaust flow, a technique known as pulse turbocharging has been developed and become the dominant technology. Pulse turbocharging minimizes the expansion losses by attaching the turbocharger to a small exhaust manifold, subjecting the turbocharger to the full transient of the discrete exhaust valve events. The net loss is
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less than that which occurs in the larger manifolds of a constant-pressure system, but, as a trade-off, the efficiency of the turbocharger subjected to pulsating flow is typically lower. A detailed description of pulse turbocharging has been given by Heywood (1998).
Turbochargers increase the efficiency and performance of diesel engines by extracting more power out of a given engine. Recycling energy from exhaust gases, turbochargers use that gas to turn a turbine, which in turn spins an air pump, which subsequently forces compressed air into the engine’s cylinders. Without a turbocharger, a diesel engine does not accelerate as fast as a gasoline engine. However, a turbocharged diesel overcomes this by forcing more air into the engine.
Honeywell estimates the “turbo effect” of adding a turbocharger to a regular diesel engine to be 70% additional fuel economy. According to a marketing research of Gabelli & Company, Inc. in 2004, the global turbocharger market is approximately 15 million units. Turbochargers are sold, on average, for about $200 each. According to the researcher of the report, David (2004), Turbochargers in the personal vehicle market represent a significant opportunity for the turbocharger or turbocharged engine manufacturers and companies.
Thus, due to the market opportunities of turbochargers, continuous efforts have been made to improve efficiency and matching of rotary machines with internal combustion engine over the widest possible range of operating conditions.
Ceausu (2006) mentioned that the typical boost provided by a turbocharger is 6 to 8 psi. Since normal atmospheric pressure is 14.7 psi at sea level, turbocharger is getting about 50 percent more air into the engine. Therefore, 50 percent more power