An integrated approach to the aero-mechanical optimisation of turbo compressors

The design of turbomachinery for high-technology products such as gas turbines, turbochargers and large industrial machinery has always embraced the latest analysis techniques to ensure that new designs reach higher levels of aerothermal performance with acceptable mechanical integrity. The challenge to maximize performance remains, but over the last decade, new issues have come to prominence to rival the fluid and structural aspects. Emphasis is now placed on the ability to design more nearly 'right-first-time' at low cost to shorten product entry into service and to further improve competitiveness. The present topical issues are numerical optimization, inclusion of more detail in the simulations and the more complete integration of the computational fluid dynamic (CFD) design process with preliminary aerodynamic design and with finite element (FE) mechanical analysis techniques. This paper describes an integrated turbomachinery design system applied to the design of centrifugal turbocompressors that can be applied in an optimizing environment. It explains in some detail the preliminary design approach where significant improvements have been made over recent years. Examples drawn from industry are used to illustrate the current state of art of CFD and FE as applied to turbochargers and industrial compressors.