Research into the Operation of Turbocharger Components in an Internal Combustion Engine

A turbocharger is a combination of two blade-type machines (compressor and turbine), the development of which requires detailed research and design work. High quality is required for the manufacturing of turbocharger elements, including the compressor and the turbine stages, bearing assembly, rotor and rotor balancing. This paper presents the results of the research into the turbocharger components in an internal combustion engine: gas dynamics at the compressor and the turbine stages, as well as the thermal, deformed state and oil consumption in the bearing assembly. A computational 3D model of the turbocharger with regard to the gas-dynamic, thermal and stress-strain state, as well as oil distribution is created to investigate characteristics of the turbocharger as it undergoes design changes. Theoretical and experimental studies on the thermal and stress-strain states of the turbocharger bearing assembly are conducted. It is established that thermal deformations of the turbocharger parts lead to an increase in the clearances in the turbocharger bearings of up to 0.013 mm. A hydraulic calculation of the bearing lubrication system is performed with and without taking into account thermal deformations. It is determined that the use of an oil distribution groove in the radial bearing does not affect the amount of oil flowing to the axial bearing. It is shown that in a turbocharger with dimensions as those under investigation, it is recommended to use radial bearings without an oil distribution groove.

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