Numerical analysis of flow interaction of turbine system in two-stage turbocharger of internal combustion engine

To reach the goal of energy conservation and emission reduction, high intake pressure is needed to meet the demand of high power density and high EGR rate for internal combustion engine. Present power density of diesel engine has reached 90KW/L and intake pressure ratio needed is over 5. Two-stage turbocharging system is an effective way to realize high compression ratio. Because turbocharging system compression work derives from exhaust gas energy. Efficiency of exhaust gas energy influenced by design and matching of turbine system is important to performance of high supercharging engine. Conventional turbine system is assembled by single-stage turbocharger turbines and turbine matching is based on turbine MAP measured on test rig. Flow between turbine system is assumed uniform and value of outlet physical quantities of turbine are regarded as the same as ambient value. However, there are three-dimension flow field distortion and outlet physical quantities value change which will influence performance of turbine system as were demonstrated by some studies. For engine equipped with two-stage turbocharging system, optimization of turbine system design will increase efficiency of exhaust gas energy and thereby increase engine power density. However flow interaction of turbine system will change flow in turbine and influence turbine performance. To recognize the interaction characteristics between high pressure turbine and low pressure turbine, flow in turbine system is modeled and simulated numerically. The calculation results suggested that static pressure field at inlet to low pressure turbine increases back pressure of high pressure turbine, however efficiency of high pressure turbine changes little; distorted velocity field at outlet to high pressure turbine results in swirl at inlet to low pressure turbine. Clockwise swirl results in large negative angle of attack at inlet to rotor which causes flow loss in turbine impeller passages and decreases turbine efficiency. However negative angle of attack decreases when inlet swirl is anti-clockwise and efficiency of low pressure turbine can be increased by 3% compared to inlet condition of clockwise swirl. Consequently flow simulation and analysis are able to aid in figuring out interaction mechanism of turbine system and optimizing turbine system design.