Turbocharger Design 

Custom Performance Billet Compressor Impellers
World's first Reverse Pitched Compressor Impeller Blade

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.

5 Axis CNC Milling of Billet Impeller
Partially Machined Compressor Impeller

Impeller Design

Surface Modelling of Turbo Impeller
3D CAD Modelling of Compressor Impeller

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

Tractor Pulling HX60 Turbine Housing
Custom Performance HX60 Turbine Housing

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.