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Design, Optimization, Analysis and Testing of Additive Manufactured Compressor Stage Using COTS Turbocharger Driven Custom Test Rig

Walker, Gabriel T
http://orcid.org/0000-0002-2959-6261
http://rave.ohiolink.edu/etdc/view?acc_num=ucin1595845858246855

Abstract Details

2020, MS, University of Cincinnati, Engineering and Applied Science: Aerospace Engineering.
The first stage of an axial compressor was designed and optimized using 1D results from 3D CFD analysis. The compressor was based off of a small commercial jet engine compressor. Structural and modal analysis were performed on the compressor to ensure safety during testing. Modal analysis results were compared to Scanning Laser Vibrometry results. A custom test rig was designed and built utilizing a COTS turbocharger. Additive manufacturing was used to produce custom parts for the test rig, including the compressor test articles. Measurements of the flow were taken to find the performance characteristics of the turbine and custom compressor. The data was acquired using Labview and various COTS measurement devices. Issues with minimum thickness and high centrifugal loads led to multiple design changes which limited the expected performance of the compressor. Complications with additive manufacturing may have also reduced the performance of the compressor. Experimentation was performed at low speeds first. The test rig failed at around 60% design speed, likely due to issues with the custom compressor mounting plate. Performance characteristics were calculated with the limited data and speed lines were generated. The data was compared to the results from CFD analysis. The optimization system was shown to be useful in increasing the performance of a compressor stage. It was concluded that a low cost custom test rig using a turbocharger is a viable solution for small compressor testing. Additive manufacturing was shown to be useful in producing one-off custom designs, though is not a perfect solution. The overall process is a useful process for rapid development and testing of custom compressor designs for small engine applications.
Mark Turner, Sc.D. (Committee Chair)
Paul Orkwis, Ph.D. (Committee Member)
Fred Schauer, Ph.D. (Committee Member)
194 p.
Aerospace Materials
Compressor Design; Turbomachinery; Optimization; Structural Analysis; CFD Analysis; Modal Analysis

Recommended Citations

Citations

  • Walker, G. T. (2020). Design, Optimization, Analysis and Testing of Additive Manufactured Compressor Stage Using COTS Turbocharger Driven Custom Test Rig [Master's thesis, University of Cincinnati]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1595845858246855

    APA Style (7th edition)

  • Walker, Gabriel. Design, Optimization, Analysis and Testing of Additive Manufactured Compressor Stage Using COTS Turbocharger Driven Custom Test Rig. 2020. University of Cincinnati, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ucin1595845858246855.

    MLA Style (8th edition)

  • Walker, Gabriel. "Design, Optimization, Analysis and Testing of Additive Manufactured Compressor Stage Using COTS Turbocharger Driven Custom Test Rig." Master's thesis, University of Cincinnati, 2020. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1595845858246855

    Chicago Manual of Style (17th edition)

ucin1595845858246855
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This open access ETD is published by University of Cincinnati and OhioLINK.