Aerodynamic instabilities modeling under asymmetric boundary in a centrifugal compressor for turbocharger

The increasing demand for compression systems with high pressure ratio and wide safety margin has set new prerequisites for designers to meet the industrial needs without increasing the manufacturing costs excessively. In this work, the turbulent stability of the vaneless diffuser of the centrifugal compressor was analyzed. Unsteady Reynolds-averaged numerical simulations of the isolated diffuser and full annular diffuser with or without circumferential asymmetric boundary conditions downstream were performed. And a continuous adjoint approach was adopted, which is rarely applied in the stability analysis of compressor flow. Then, the origin of instability under different inflow and outflow conditions was sought with a sensitivity analysis. The prediction of the growth rate reveals that the flow near the shroud dominates the global stability of the diffuser. When connected with an impeller in the upstream direction, the most unstable region is localized at the backflow regions near the outlet. The wave number, however, is altered under the impact of the jet-wake flow. When connected to a circumferential asymmetric condition, the structural sensitivity of the vaneless diffuser with a radius ratio of 1.53 indicates that the interaction between the inlet reverse flow and outlet backflow is responsible for the occurrence of stall. The most unstable regions are localized at the region 90°–135° away from the volute tongue. The present work mainly contributes to the instabilities identification with novel sensitivity methods under asymmetric boundary conditions.

Effects of Non-Axisymmetric Volute On Rotating Stall in the Vaneless Diffuser of Centrifugal Compressors

Rotating stall is an important unstable flow phenomenon that leads to performance degradation and limits the stability boundary in centrifugal compressors. The volute is one of the sources inducing non-axisymmetric flows in centrifugal compressors, which has an important effect on compressors' aerodynamic performance. However, the influence of volute on rotating stall is unclear. Therefore, the effects of volute on rotating stall behavior have been explored in this paper by experiments and numerical simulations. The frequency of the rotating stall captured by the experiments is 43.9% of the impeller passing frequency, while it is 44.7% of IPF calculated from the numerical results, which proves the accuracy and capability of the numerical method in this work to study the rotating stall behavior. The flow fields from CFD simulations further reveal that one stall cell initializing in a particular location deforms into several stall cells while rotating along the circumferential direction and becomes much smaller in a specific location during the evolution process, and finally, it is suppressed in another specific location as a result of the distorted flow field caused by the volute. By optimizing volute geometry to reduce the distortion of the flow field, it is expected that the rotating stall can be weakened or suppressed, which is helpful to extend the stable operating range of centrifugal compressors.

Vaneless Diffuser Performance in a Super-Critical Carbon Dioxide Centrifugal Compressor With Real Gas Effects

Super-critical Carbon dioxide (s-CO2) flows are neither incompressible nor ideal gas flows. Unlike perfect gases, the enthalpy of s-CO2 near the critical point is a strong function of pressure. Incorporation of these effects is necessary for accurate modeling of flows in centrifugal compressor vaneless diffusers. This study reviews the existing vaneless diffuser modeling technique, and modifications are made to incorporate real gas effects. Like the existing procedure, the proposed formulation does not require multiple iterations for convergence. The results are obtained in a single step using a marching technique. Hence, this model can be incorporated in standard centrifugal compressor design and analysis tools, especially for super-critical carbon dioxide flows, subject to experimental validation.

Rotating Mechanism of Diffuser Stall in a Centrifugal Compressor With Vaneless Diffuser

The rotating mechanism of diffuser stall in a centrifugal compressor with a vaneless diffuser is investigated via experimental and computational analyses. Diffuser stall is generated as the mass flow rate decreases, and it rotates at 25%–30% of the impeller rotational speed. First, a diffuser stall cell emerges at 180° from the cutoff by the hub-side boundary layer separation. Subsequently, the diffuser stall cell develops further owing to boundary layer separation accumulation and an induced low-velocity area. The low-velocity region forms a blockage across the diffuser passage span. The diffuser stall cell expands owing to the boundary layer separations that occurred on the shroud and hub wall by turns. Finally, the diffuser stall cell vanishes when it passes the cutoff because mass flow recovery occurred. Furthermore, the static pressure ahead of the rotating stall decreases because of the merging of the impeller discharge flow and the reverse flow from the casing. Accordingly, a reverse flow occurred owing to the evolution of the separation vortex at the diffuser exit. In addition, the flow angle decreases by the merging of the impeller discharge flow and reverse flow from the casing. Therefore, boundary layer separations start occurring on the shroud and hub wall ahead of the stall cell. The rotating mechanism of the diffuser stall is induced by the reverse flow development and a decrease in the flow angle ahead of the stall cell.