Port Design Study in Waste-gate Turbocharger with Numerical Simulation

Paper #:
  • 2017-01-2411

Published:
  • 2017-10-08
Abstract:
A smart waste-gate (WG) turbocharger controls boost by bypassing turbine flow through the WG port which allows optimizing both low and high speed engine performance. However, the WG port in the turbine housing involves much complex geometry which leads to potential higher thermal stress and plastic strain if design is improper. This paper first presents the common thermal cracking problems at port zone and then shows finite element analysis (FEA) results for one of the design. The predicted location correlates well with the observed failure port location. Then a design study of key parameters for the port is conducted with same boundary conditions. The key parameters include height H, inner diameter D and inner diameter fillet r of the port. Totally 13 designs are studied under package and performance limitation. Accumulated plastic strain from FEA is used to evaluate the effect of design changes. Curves are plotted to reflect the relationship between accumulate plastic strain and design parameters. These curves clearly show how to control height, inner diameter and fillet under package limitation to reduce the plastic strain level. This study provides a knowledge base for the design of WG port and can be a guide at the initial design stage. Keywords: Port Design, Design Study, Finite Element Analysis, Accumulated Plastic Strain, Waste-gate Turbocharger
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