Turbocharger Model

1. Open the Turbocharger model file and go to quality criteria and go to presentation parameters; tick mark on draw cons option under the visualization bar and also go to the details on demand effect and select all details.

2. Select cross hatches and select not operator in PID mode and select PID region and we notice that there are some errors. Looking at the model we notice that there are some unwanted surfaces which need to be deleted and there are some single cons as well.

3. First, we notices that there is an extra surface on the compressor casing, which is unwanted. So, we delete it.

4. Second, we notice that at the of the model the at the top cover near the blades there are single cons, which we need to fix. We go to faces module and select new optionand go to fitted option and select loop to avoid selecting all error surfaces seperately. Now we get the desired result.

5. Now we need to fix the impeller casing cover, which we found to be broken. To fix this we need to create hot points module and select parametric option to create a proper suface. So, we need to select the single cons on which the hot points need to be created and need to mention the distance(0.5) and then again select the parametrics option to draw hot points on the opposite side as well with distance(0.5). Now we notice that we not getting the exact result we want. So, we draw hot points again in between the created hot points and then we get the desired result.

6. Now we have another error which looks like an extruded part. But it is a curved plane which is intersecting with the other surface. To, eliminate this error we need to go to the cons module and use project option and select the round part and the face attached to it. The intersection is now eliminated and 2 different surfaces are created. Now there is the round part which is intersecting with the remaining surfaces, which has to be eliminated. Now we delete the extruded part.

7. Now if we press cntrl+shift we to find errors, if we find any surface intersections we need to eliminate it by using project project option.

8. After all errors are clear, we set PID\'s for all the surfaces; which are impeller casing, compressor casing cover, blades stage 1 & 2, shaft rotar, impeller, etc.

9. Now we notice that the blades are not single entities; they are all different entities. To make it a single entity we use the topo option under faces module and intersect all the blades of stage 1 & 2. Now we notice that some surface are intersecting with blades of stage 1 & 2 with the shaft rotar. We need to use the project option to align the surfaces and delete the unwanted surface.

10. Now we perform the same step with impeller blades and we notice that the insection doesn\'t appear, so we use the option cut to match the size of blades base with the shaft rotar base. After getting the proper intersection we need to delete the base which is intersecting with the impeller casing cover.

11. Now after all the errors are cleaned we can perform the mesh(tria). As mentioned in the question above the lenght of the mesh of blades stage 1&2 and shaft rotar is 1mm, impeller mesh size is 2mm, compressor, impeller casing and inlet casing cover are given the mesh size of 5mm. After meshing all the surfaces with specified lenghts, we notice that the mesh on certain geometries are coinciding with each other. And we notice some unnecessary parts which are not needed.

12. To delete those parts we use the project option and intersect all the required surfaces and then delete the unwanted parts. Now we notice that the places where there is an interesection the mesh is uneven or inconsistent.

13. If we create a surface surrounding the geometry where the mesh is inconsistent by using the cut option and create points and make a surface and specify the lenght which is in between the lenght of the intersecting surfaces we get consistent mesh.

14. So, after meshing separately with a common lenght, we get a consistent mesh throughout the geometry.

15. Now to perform volumetric mesh we need to cover all the opened areas and create a new surface to close all the surfaces and mesh them all after assigning separate PID\'s to those closed surfaces.

16. We go to volume mesh and use the volume module and go to define. It will show all the volumes. Now we need to check which volumes are necessary for CFD analysis. Both the compressor casing and impeller casing are not required as the fuilds doesn\'t flow to the outer casings. And also the shaft rotor and blades are not required and are needed to be deleted.

17. Now we perform unstructured mesh module and go to tetra CFD analysis.