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Centrifugal Compressor Stall Control by the Application of Engineered Surface Roughness on Diffuser Shroud Using
Amjid Khan1, Muhammad Irfan2, Usama Muhammad Niazi1
1Faculty of Mechanical Engineering, National University of Technology, Islamabad 44,000, Pakistan.
Materials (Basel, Switzerland)
|April 30, 2021
Summary
Surface roughness effectively controls stall in turbocharger compressors, expanding the operating range by up to 18% and improving stall margin. This passive flow control method enhances turbocharger performance at low mass flow rates.
Area of Science:
- Aerospace Engineering
- Fluid Dynamics
- Mechanical Engineering
Background:
- Engine downsizing necessitates turbocharger centrifugal compressors operating at low mass flow rates.
- Low mass flow rates can induce fluid flow instabilities, notably stall, impacting compressor performance.
- Passive flow control methods are sought to mitigate these instabilities.
Purpose of the Study:
- To evaluate the impact of surface roughness on turbocharger centrifugal compressor performance.
- To investigate surface roughness as a passive flow control method for stall reduction.
- To analyze the effect of varying surface roughness magnitudes on compressor operating range and stall margin.
Main Methods:
- Numerical simulations of the SRV2-O compressor stage (validated against experimental data from the German Aerospace Center).
- Simulations conducted from stall to choke conditions at 2.55 kg/s mass flow rate and 50,000 rpm.
- Application of surface roughness (0-200 μm) on the diffuser shroud to assess flow instability control.
Main Results:
- A completely rough diffuser shroud demonstrated significant stall control.
- The compressor's operating range increased from 16% to 18%.
- Stall margin improved from 5.62% to 7.98% with applied surface roughness.
Conclusions:
- Surface roughness is an effective passive flow control strategy for reducing flow instability in turbocharger compressors.
- The application of surface roughness on the diffuser shroud enhances compressor operating range and stall margin.
- This research offers a practical method for turbocharger manufacturers to improve compressor performance and reduce flow instabilities.
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