Turbocharger Design
Whether you wish us to redesign an existing turbocharger or want us to deliver an entirely different, new, optimized turbocharger; we can help!
We pride ourselves in being one of only a few turbocharger manufacturers that offer reverse engineering, Computer Aided Design and Computer Aided Engineering solutions along with the ability to not only copy and reproduce, but also expand, improve and optimize existing turbochargers and their components.
We do not cut corners in supplying you with the best turbocharger product in the market.
We represent QUALITY
We are not to be mistaken with CHEAP, "you give us and we give you MAYBE the same part" suppliers you find on the internet and around the world. These CHEAP suppliers, most of the time cut corners, don't deliver quality and often don't understand the true functionality of turbochargers. These CHEAP manufacturers merely take existing products and reproduce them to the best of their abilities, which often leads to poor Journal Bearing and Thrust Bearing tolerances along with inadequate material physical properties.
In a nut shell: These turbochargers often have failures, due to excessive wear and material failures.
NIAMA-REISSER, LLC delivers INEXPENSIVE turbocharger parts, custom design and manufacturing. We tailor each and every turbocharger to its specific operating application.
If the application demands it, we design, optimize and manufacture billet compressor impellers, billet or cast center housing rotating assemblies, stainless steel turbine housings and inconel turbine impellers from the best suited materials.
Turbocharger Design Workflow
Reverse Engineering
White-Light (Optical) scanning of existing turbocharger components .
CAD Modelling
From scanned point cloud data, generate 3D Model of existing parts.
CAD Optimization
Change existing CAD geometries to attain desired performance levels.
CAD Assembly
Optimizing a Compressor Impeller in CFD requires reverse engineering the following parts:
1) Diffusor Plate
2) Compressor Housing / Cover
3) Compressor Impeller
After all parts have been successfully scanned, modeled and / or optimized, all three parts have to be virtually assembled to match real conditions.
CAD Migration
The CAD Assembly File will now be migrated from our CAD Software into our CAE / CFD Software ANSYS Workbench.
CAE Setup
The assembly parts have to be imported, healed, solidified and defined.
Negative Volume Meshing
The solid volume parts are going to be subtracted from the negative volume surrounding the compressor housing's involute, around the compressor impeller and in between the compressor impeller and diffusor plate.
Creating Negative Volume Zones
The negative volume zones are defined by selecting which fluid volume zones (negative volumes) are going to be stationary and which are going to be revolving.
Setting up Negative Volume Interfaces
Definition on how the different fluid zones are going to interact with each other.
Defining Boundary Conditions
Defining the Impeller Speed, the Inlet and Outlet interfaces. The inlet is set to atmospheric conditions, while the outlet has to be restricted to the real life test engine rpm, displacement and boost pressure (cfm restrictions), since a baseline to a real world test has to be achieved.
High Performance Computing
Transient Analysis Computing takes days, if not weeks to complete, even with high performance computing cluster servers.
Optimize CAD to Attain Desired Performance
After the baseline is created with AS-IS parts (real world baseline), a new optimized model with identical ANSYS CAE setup has to be imported into ANSYS and run, to compare to the baseline setup. This step has to be repeated numerous times, before the desired performance gains are generally achieved.
Generating 2-D Drawings from Optimized CAD
Before parts can be manufactured using CNC equipment, tolerances and dimensions have to be set on paper drawings.
Manufacture Optimized Turbocharger Parts
Once drawings are generated, the parts can either be milled, turned, EDM, Cast, Electron Beam Welded and Direct Metal Lasered.
Impeller Design
Over the past seven years, we have developed our own proprietary process of modeling entire compressor impellers from scratch.
Our engineers and designers have the unique ability to model using surfaces, splines, points, curves. This enables us to model a complete compressor, turbine, centrifugal, etc. impellers using nothing but surfaces, that we generate ourselves.
We don't have to rely on programs and algorithms to dictate our blade geometries. We have the means and know-how to modify the minutest of blade geometry characteristics.
Housing Design
The hardest of geometries are "Free Form" geometries that start as large rectangular shapes and morph from their rectangular shapes to circular, radially cross-section reducing, geometries.
The best example here for are compressor or turbine housing turbocharger parts.
We have mastered the art of designing and manufacturing 100% custom turbine housings.
CHRA Design
At the heart of any turbocharger lies the center housing rotating assembly. To enable these housings to function properly, we have devised the best possible high speed ceramic ball bearing setup on the market. To make things better, our heavy-duty or direct replacement CHRA bearing cartridges for Garrett and Borg Warner make it easy to change the factory non-serviceable CHRAs into performance driven serviceable units.