ENGR​ ​114

Final​ ​Project
Michael​ ​Borisenko
 I​ ​decided​ ​to​ ​model​ ​a​ ​turbocharger​ ​as​ ​my​ ​final​ ​project.​ ​I​ ​always​ ​had​ ​an​ ​interest​ ​in​ ​turbos
it​ ​fulfilled​ ​the​ ​project​ ​requirements.​ ​During​ ​the​ ​modeling​ ​process​ ​I​ ​had​ ​to​ ​came​ ​across​ ​a​ ​few
challenges​ ​that​ ​required​ ​me​ ​to​ ​use​ ​modeling​ ​techniques​ ​we​ ​had​ ​not​ ​covered​ ​or​ ​talked​ ​about​ ​in
class.

Advanced​ ​Lofts:
Right​ ​off​ ​the​ ​bat​ ​I​ ​started​ ​with​ ​trying​ ​to​ ​model​ ​the​ ​turbine​ ​housing.​ ​I​ ​needed​ ​to​ ​create​ ​a
spiraling​ ​tube​ ​that​ ​converged.​ ​After​ ​many​ ​attempts​ ​with​ ​varying​ ​amounts​ ​of​ ​success​ ​I​ ​found​ ​a
way​ ​to​ ​do​ ​it.

Figure​ ​1:​ ​Loft​ ​sketches

I​ ​sketched​ ​a​ ​circle​ ​then​ ​I​ ​inserted​ ​a​ ​spiral.​ ​Making​ ​sure​ ​both​ ​the​ ​spiral​ ​and​ ​the​ ​circle
were​ ​still​ ​visible​ ​I​ ​went​ ​through​ ​and​ ​sketched​ ​a​ ​total​ ​of​ ​four​ ​circles​ ​on​ ​the​ ​front​ ​and​ ​right
planes.​ ​I​ ​put​ ​a​ ​construction​ ​line​ ​through​ ​the​ ​center​ ​of​ ​the​ ​circles​ ​so​ ​that​ ​I​ ​was​ ​able​ ​to​ ​add
peirce​ ​relations​ ​from​ ​the​ ​edge​ ​of​ ​the​ ​circle​ ​to​ ​the​ ​inner​ ​circle​ ​and​ ​to​ ​the​ ​outer​ ​spiral.​ ​This​ ​way​ ​it
made​ ​for​ ​easy​ ​editing​ ​of​ ​the​ ​model​ ​down​ ​the​ ​road.​ ​The​ ​smallest​ ​and​ ​last​ ​circle​ ​I​ ​made​ ​by
sketching​ ​a​ ​line​ ​on​ ​the​ ​top​ ​plane,​ ​specifying​ ​the​ ​angle​ ​from​ ​the​ ​x-axis​ ​and​ ​surface​ ​extruded​ ​it
straight​ ​up.​ ​You​ ​can​ ​use​ ​a​ ​reference​ ​plane​ ​instead​ ​but​ ​that​ ​requires​ ​an​ ​additional​ ​3d​ ​sketch.​ ​I
then​ ​used​ ​the​ ​surface​ ​as​ ​a​ ​sketch​ ​plane​ ​where​ ​I​ ​drew​ ​the​ ​last​ ​and​ ​fifth​ ​circle.​ ​After​ ​the
sketches​ ​were​ ​completed​ ​I​ ​was​ ​ready​ ​to​ ​loft​ ​it.​ ​In​ ​the​ ​loft​ ​feature​ ​you​ ​select​ ​all​ ​of​ ​the​ ​circles​ ​in
order,​ ​largest​ ​to​ ​smallest​ ​or​ ​smallest​ ​to​ ​largest,​ ​doesn’t​ ​matter​ ​which​ ​way​ ​you​ ​do​ ​it​ ​but​ ​it​ ​has​ ​to
be​ ​in​ ​order,​ ​than​ ​I​ ​selected​ ​the​ ​spiral​ ​and​ ​the​ ​inner​ ​circle​ ​as​ ​guide​ ​curves​ ​to​ ​the​ ​loft.​ ​It​ ​came
out​ ​beautifully.​ ​In​ ​the​ ​end​ ​it​ ​used​ ​6​ ​sketches​ ​and​ ​a​ ​spiral.
One​ ​error​ ​I​ ​kept​ ​having​ ​was​ ​that​ ​the​ ​guide​ ​curves​ ​didn’t​ ​intersect​ ​the​ ​sketches​ ​because
I​ ​tried​ ​making​ ​one​ ​guide​ ​circle​ ​through​ ​the​ ​center​ ​of​ ​the​ ​varying​ ​diameter​ ​circles.​ ​When​ ​you
sketch​ ​a​ ​circle​ ​it​ ​is​ ​not​ ​a​ ​closed​ ​surface​ ​thus​ ​the​ ​guide​ ​curves​ ​have​ ​to​ ​intersect​ ​or​ ​coincide​ ​with
the​ ​edges​ ​of​ ​the​ ​sketched​ ​circles.

Figure​ ​2:​ ​completed​ ​loft

Creating​ ​the​ ​turbine​ ​and​ ​compressor​ ​wheels​ ​also​ ​took​ ​some​ ​ingenuity​ ​with​ ​the​ ​loft
command.​ ​I​ ​used​ ​2​ ​rectangles​ ​offset​ ​a​ ​height​ ​and​ ​angle​ ​and​ ​a​ ​3d​ ​spline​ ​as​ ​a​ ​guide​ ​curve.
 Turbine​ ​loft​ ​sketches

Another​ ​difficulty​ ​I​ ​ran​ ​into​ ​was​ ​that​ ​I​ ​wanted​ ​the​ ​inside​ ​cut​ ​to​ ​slim​ ​down​ ​and​ ​get​ ​thinner
with​ ​the​ ​pipe.​ ​Therefore​ ​I​ ​used​ ​a​ ​similar​ ​technique​ ​as​ ​with​ ​the​ ​circular​ ​lofted​ ​tube​ ​but​ ​this​ ​time​ ​I
used​ ​rectangles​ ​along​ ​with​ ​the​ ​outer​ ​spiral​ ​and​ ​inner​ ​circle​ ​and​ ​I​ ​lofted​ ​cut.

Figure​ ​4:​ ​section​ ​view​ ​showing​ ​lofted​ ​cut

Before​ ​I​ ​found​ ​the​ ​lofted​ ​cut​ ​command,​ ​on​ ​the​ ​turbine​ ​housing​ ​I​ ​surface​ ​lofted​ ​the
rectangular​ ​spiral​ ​instead​ ​of​ ​lofted​ ​cut.​ ​Then​ ​I​ ​thickened​ ​cut​ ​with​ ​the​ ​surface​ ​to​ ​achieve​ ​the
same​ ​result.​ ​However​ ​the​ ​thicken​ ​cut​ ​left​ ​the​ ​start​ ​and​ ​end​ ​edges​ ​uncut​ ​so​ ​I​ ​had​ ​to​ ​sketch
rectangles​ ​and​ ​extrude​ ​cut​ ​the​ ​edges.​ ​I​ ​learned​ ​that​ ​if​ ​you​ ​cut​ ​the​ ​separate​ ​solid​ ​bodies​ ​with​ ​a
cut,​ ​a​ ​dialog​ ​box​ ​pops​ ​up​ ​asking​ ​which​ ​body​ ​you​ ​would​ ​like​ ​to​ ​keep.

Figure​ ​5:​ ​thicken​ ​cut

Flow​ ​Simulation:
I​ ​wanted​ ​to​ ​do​ ​a​ ​flow​ ​simulation​ ​of​ ​the​ ​compressor​ ​assembly​ ​(compressor​ ​housing​ ​and
the​ ​compressor​ ​itself).​ ​However​ ​in​ ​FlowXpress​ ​you​ ​do​ ​not​ ​have​ ​the​ ​option​ ​to​ ​have​ ​rotation.​ ​I
wanted​ ​to​ ​model​ ​it​ ​with​ ​the​ ​compressor​ ​spinning​ ​at​ ​100,000​ ​RPM​ ​(typical​ ​for​ ​gasoline​ ​engine
turbochargers).​ ​Therefore​ ​I​ ​used​ ​the​ ​full​ ​Flow​ ​Simulation​ ​package​ ​which​ ​has​ ​much​ ​more
capabilities.​ ​In​ ​Flow​ ​Simulation​ ​you​ ​can​ ​have​ ​internal​ ​or​ ​external​ ​flow​ ​analysis,​ ​model​ ​and
account​ ​for​ ​heat​ ​conduction,​ ​radiation,​ ​gravity,​ ​and​ ​rotation.​ ​You​ ​can​ ​have​ ​time​ ​dependent
studies​ ​when​ ​you​ ​have​ ​oscillations​ ​or​ ​sliding​ ​rotation.​ ​Flow​ ​Simulation​ ​has​ ​~30​ ​different
gasses​ ​and​ ​~30​ ​liquids,​ ​non-newtonian​ ​fluids,​ ​compressible​ ​liquids​ ​and​ ​steam​ ​to​ ​use​ ​as​ ​the
evaluated​ ​fluid.
The​ ​very​ ​first​ ​thing​ ​you​ ​must​ ​do​ ​before​ ​you​ ​begin​ ​an​ ​internal​ ​flow​ ​simulation​ ​is​ ​to​ ​make
sure​ ​the​ ​model​ ​or​ ​assembly​ ​is​ ​fully​ ​watertight.​ ​Fortunately​ ​there​ ​is​ ​a​ ​wizard​ ​that​ ​helps​ ​you
create​ ​caps​ ​on​ ​all​ ​openings.​ ​You​ ​can​ ​then​ ​specify​ ​the​ ​boundary​ ​conditions​ ​on​ ​any​ ​surface,
usually​ ​on​ ​the​ ​inside​ ​of​ ​the​ ​caps.​ ​You​ ​can​ ​specify​ ​a​ ​pressure,​ ​mass​ ​flow​ ​rate,​ ​volume​ ​flow​ ​rate,
and​ ​wall​ ​conditions.
After​ ​you​ ​have​ ​set​ ​all​ ​your​ ​boundary​ ​conditions​ ​and​ ​in​ ​my​ ​case​ ​the​ ​rotating​ ​regions,​ ​you
have​ ​to​ ​set​ ​some​ ​goals.​ ​Flow​ ​Simulation​ ​will​ ​not​ ​stop​ ​without​ ​goals,​ ​it​ ​can​ ​continue​ ​refining
recalculating​ ​the​ ​results​ ​indefinitely,​ ​so​ ​it​ ​is​ ​important​ ​to​ ​set​ ​some​ ​goals.​ ​Solidworks​ ​treats​ ​the
goals​ ​as​ ​convergence​ ​goals,​ ​as​ ​the​ ​value​ ​of​ ​the​ ​goals​ ​converges​ ​to​ ​a​ ​finite​ ​number​ ​it​ ​stops
running​ ​the​ ​simulation.​ ​A​ ​global​ ​goal​ ​is​ ​a​ ​physical​ ​parameter​ ​of​ ​the​ ​entire​ ​model​ ​that​ ​you​ ​are
simulating​ ​(ie.​ ​maximum​ ​temperature),​ ​a​ ​point​ ​goal​ ​is​ ​a​ ​pressure/velocity/temperature​ ​at​ ​a
specific​ ​point​ ​(useful​ ​when​ ​comparing​ ​to​ ​real​ ​world​ ​probe​ ​values),​ ​surface​ ​goals​ ​are
parameters​ ​of​ ​a​ ​surface​ ​usually​ ​an​ ​inlet​ ​or​ ​outlet,​ ​a​ ​volume​ ​goal​ ​is​ ​a​ ​parameter​ ​within​ ​a
specified​ ​volume,​ ​and​ ​equation​ ​goals​ ​allow​ ​you​ ​to​ ​combine​ ​any​ ​and​ ​all​ ​the​ ​goal​ ​types​ ​(usually
outlet​ ​minus​ ​inlet​ ​to​ ​find​ ​pressure/velocity/flowrate​ ​difference).
After​ ​you​ ​have​ ​your​ ​goals​ ​set​ ​you​ ​are​ ​ready​ ​to​ ​run​ ​your​ ​simulation.​ ​After​ ​the​ ​study​ ​is
complete​ ​and​ ​you​ ​have​ ​your​ ​results​ ​there​ ​are​ ​many​ ​ways​ ​to​ ​display​ ​and​ ​analyze​ ​them.​ ​One​ ​of
the​ ​simplest​ ​and​ ​most​ ​effective​ ​is​ ​a​ ​cut​ ​plot.​ ​A​ ​cut​ ​plot​ ​is​ ​a​ ​cross​ ​section​ ​with​ ​a​ ​color​ ​coded
contour​ ​map​ ​displaying​ ​the​ ​differences​ ​in​ ​a​ ​parameter​ ​across​ ​the​ ​cross​ ​section.​ ​However​ ​in
my​ ​case​ ​the​ ​cross​ ​section​ ​view​ ​ended​ ​up​ ​messy​ ​so​ ​i​ ​didn’t​ ​use​ ​cut​ ​plots.​ ​What​ ​i​ ​found​ ​more
useful​ ​where​ ​flow​ ​trajectories,​ ​in​ ​my​ ​case​ ​i​ ​set​ ​these​ ​lines​ ​to​ ​track​ ​the​ ​pressure​ ​and​ ​velocity​ ​of
the​ ​fluid​ ​(air)​ ​as​ ​it​ ​went​ ​through​ ​the​ ​turbocharger.​ ​You​ ​can​ ​edit​ ​the​ ​style​ ​and​ ​amount​ ​of​ ​lines,
you​ ​can​ ​also​ ​set​ ​a​ ​range​ ​of​ ​values​ ​for​ ​the​ ​color​ ​gradient​ ​to​ ​be​ ​as​ ​precise​ ​as​ ​you​ ​want​ ​to​ ​be​ ​in​ ​a
specific​ ​range​ ​that​ ​may​ ​be​ ​smaller​ ​than​ ​the​ ​total​ ​range.

Figure​ ​6:​ ​fluid​ ​velocity​ ​through​ ​compressor

I​ ​also​ ​used​ ​a​ ​surface​ ​plot​ ​to​ ​show​ ​a​ ​parameter​ ​across​ ​a​ ​single​ ​surface.​ ​I​ ​chose​ ​to
examine​ ​the​ ​air​ ​velocity​ ​across​ ​a​ ​single​ ​blade​ ​of​ ​the​ ​compressor.​ ​I​ ​hid​ ​the​ ​compressor
housing.

Figure​ ​8:​ ​fluid​ ​velocity​ ​across​ ​single​ ​blade

Solidworks​ ​can​ ​also​ ​generate​ ​a​ ​report,​ ​a​ ​word​ ​document​ ​containing​ ​all​ ​the​ ​setup
information​ ​and​ ​minimum,​ ​maximum,​ ​and​ ​average​ ​values​ ​of​ ​the​ ​temperature,​ ​velocity,​ ​volume
flow​ ​rate,​ ​mass​ ​flow​ ​rate,​ ​pressure,​ ​and​ ​much​ ​much​ ​more.
I​ ​barely​ ​scratched​ ​the​ ​surface​ ​of​ ​what​ ​you​ ​can​ ​do​ ​using​ ​Flow​ ​Simulation.

Photorealistic​ ​rendering:
The​ ​solidworks​ ​photoview​ ​360​ ​add-in​ ​is​ ​fairly​ ​straightforward.​ ​I​ ​didn't​ ​get​ ​into​ ​it​ ​very​ ​deep​ ​but
from​ ​what​ ​I​ ​used​ ​it​ ​was​ ​pretty​ ​easy​ ​to​ ​get​ ​some​ ​nice​ ​results.​ ​You​ ​set​ ​a​ ​background,​ ​position
the​ ​camera​ ​and​ ​if​ ​you​ ​go​ ​to​ ​“scene​ ​illumination​ ​proof​ ​sheet”​ ​in​ ​the​ ​“render​ ​tools”​ ​tab,​ ​it
pre-renders​ ​~15​ ​options​ ​and​ ​you​ ​can​ ​just​ ​click​ ​through​ ​and​ ​continue​ ​to​ ​refine​ ​it​ ​until​ ​you​ ​get
what​ ​you​ ​want.
 Figure​ ​10:​ ​scene​ ​illumination​ ​proof​ ​sheet
You​ ​can​ ​then​ ​set​ ​the​ ​resolution​ ​and​ ​quality​ ​and​ ​do​ ​a​ ​final​ ​render.​ ​If​ ​you​ ​set​ ​the​ ​quality​ ​to​ ​the
maximum​ ​it​ ​may​ ​take​ ​20-60​ ​minutes​ ​to​ ​render​ ​a​ ​single​ ​image​ ​depending​ ​on​ ​your​ ​CPU​ ​and
image​ ​resolution.
Figure​ ​11:​ ​low​ ​quality
Figure​ ​12:​ ​High​ ​quality