Centrifugal Compressor Stall Control by the Application of Engineered Surface Roughness on Diffuser Shroud Using Numerical Simulations

Abstract

Downsizing in engine size is pushing the automotive industry to operate compressors at low mass flow rate. However, the operation of turbocharger centrifugal compressor at low mass flow rate leads to fluid flow instabilities such as stall. To reduce flow instability, surface roughness is employed as a passive flow control method. This paper evaluates the effect of surface roughness on a turbocharger centrifugal compressor performance. A realistic validation of SRV2-O compressor stage designed and developed by German Aerospace Center (DLR) is achieved from comparison with the experimental data. In the first part, numerical simulations have been performed from stall to choke to study the overall performance variation at design conditions: 2.55 kg/s mass flow rate and rotational speed of 50,000 rpm. In second part, surface roughness of magnitude range 0–200 μm has been applied on the diffuser shroud to control flow instability. It was found that completely rough regime showed effective quantitative results in controlling stall phenomena, which results in increases of operating range from 16% to 18% and stall margin from 5.62% to 7.98%. Surface roughness as a passive flow control method to reduce flow instability in the diffuser section is the novelty of this research. Keeping in view the effects of surface roughness, it will help the turbocharger manufacturers to reduce the flow instabilities in the compressor with ease and improve the overall performance.