Computing and Library Services - delivering an inspiring information environment

Determining stress in turbocharger impellers due to component machining

Barrans, Simon, Tabriz, Md Shams E and Ellis, Christian (2017) Determining stress in turbocharger impellers due to component machining. In: ASME Turbo Expo: Turbomachinery Technical Conference & Exposition, 26-30 June 2017, Charlotte, North Carolina, USA.

[img] PDF (ASME Conference Paper) - Accepted Version
Restricted to Repository staff only

Download (1MB)


Turbocharger impeller wheels are traditionally manufactured using a casting process. However, with the improvement of multi-axial machining technology, machined impeller wheels are becoming popular among turbo machinery manufacturers due to their enhanced durability. Nonetheless, machining a complex impeller shape from a solid billet, results in tool marks being left on the component surface. As presented in this paper, repeatedly running a wheel to 5% beyond the design speed limit can result in fatigue failure initiating from the machining marks.
In this paper, the ‘as machined’ geometry of sample wheels has been determined using both CT scanning and optical surface measurement techniques. The data from these measurements has been used to generate solid CAD models suitable for finite element analysis to simulate the stress distribution of reverse engineered wheels. The maximum principal stress predicted is 15% higher than that obtained from the nominal CAD model. In order to model the measured geometry efficiently, a novel technique has been used to enforce cyclic symmetry on geometry that is not precisely cyclically symmetric.
The work has demonstrated that it is possible to predict the stress raising effect of the machining marks at the design stage. The analysis methodology presented in the paper will enable future integrated optimisation of both the design and manufacture of impeller wheels to ensure that wheels with a specified operating envelope are machined as efficiently as possible.

Item Type: Conference or Workshop Item (Paper)
Subjects: T Technology > TJ Mechanical engineering and machinery
T Technology > TS Manufactures
Schools: School of Computing and Engineering
School of Computing and Engineering > Turbocharger Research Institute
Related URLs:
References: [1] Zamarripa, A.S., Fatigue behaviour of a 2618-T6 aluminium alloy used in turbocharger compressor wheels, in Department of Mechanical Engineering. 2008, The University of Sheffield: United Kingdom. p. 189. [2] Liu, S., Liu, C., Hu, Y., Gao, S., Wang, Y., and Zhang, H., Fatigue life assessment of centrifugal compressor impeller based on FEA. Engineering Failure Analysis, 2016. 60: p. 383-390. [3] Subramani, D.A., Ramamurti, V., and Sridhara, K., Numerical analysis and experimental verification of the radial growth of a turbocharger centrifugal compressor impeller. Journel of Strain Analysis for Engineering Design, 1997. 32 No. 2: p. 119-128. [4] Miller, P.L., Oliver, J.H., Miller, D.P., and Tweedt, D.L. BladeCAD: An Interactive Geometric Design Tool for Turbomachinery Blades. in ASME 1996 International Gas Turbine and Aeroengine Congress and Exhibition. 1996. Birmingham, UK: ASME. [5] Seiler, A., Balendran, V., Sivayoganathan, K., and Sackfield, A., Reverse Engineering from Uni-Directional CMM Scan Data International Journel Advence Manufactruring Technology, 1996. 11: p. 276-284. [6] Chintalaa, G. and Gudimetla, P., Optimum material evaluation for gas turbine blade using Reverse Engineering (RE) and FEA. Procedia Engineering, 2014. 97: p. 1332-1340. [7] Shahrbaf, S., vanNoort, R., Mirzakouchaki, B., Ghassemieh, E., and Martin, N., Effect of the crown design and interface lute parameters on the stress-state of a machined crown–tooth system: A finite element analysis. Dental Materials, 2013. 29: p. 123-131. [8] Soni, K., Chen, D., and Lerch, T., Parameterization of prismatic shapes and reconstruction of free-form shapes in reverse engineering. International Journel Advence Manufactruring Technology 2008. 41: p. 948–959. [9] Carbone, V., Carocci, M., Savio, E., Sansoni, G., and Chiffre, L.D., Combination of a Vision System and a Coordinate Measuring Machine for the Reverse Engineering of Freeform Surfaces. International Journel Advence Manufactruring Technology, 2001. 17: p. 263-271. [10] Li, Y.F. and Liu, Z.G., Method for determining the probing points for efficient measurement and reconstruction of freeform surfaces. Measurement Science and Technology 2003. 14: p. 1280–1288. [11] Chang, D.Y. and Chang, Y.M., A Freeform Surface Modelling System Based on Laser Scan Data for Reverse Engineering. International Journel Advence Manufactruring Technology 2002. 20: p. 9-19. [12] Lee, S.J. and Chang, D.Y. Laser scanning probe with multiple detectors used for sculptured surface digitization in reverse engineering. in 7th International Symposium on Measurement Technology and Intelligent Instruments. 2005. Journal of Physics: Conference Series. [13] Noel, J., Advantages of CT in 3D Scanning of Industrial Parts, in 3D Scanning Technologies Magazine. 2008, North Star Imaging. p. 18-23. [14] Marton, Z.C., Rusu, R.B., and Beetz, M. On Fast Surface Reconstruction Methods for Large and Noisy Point Clouds. in IEEE International Conference on Robotics and Automation. 2009. Kobe, Japan. [15] Ye, X., Liu, H., Chen, L., Chen, Z., Pan, X., and Zhang, S., Reverse innovative design-an integrated product design methodology. Computer-Aided Design (2008) 2008. 40: p. 812–827. [16] Vickers, G.W. and Quan, K.W., Ball-Mills Versus End-Mills for Curvesd Surface Machining. Journal of Engineering Industry, 1989. 111: p. 22-26. [17] Squires, J. Understanding stepover and cusp height. 2013 [cited 2017 1 February]; Available from: [18] Sivaprasad, S., Narasaiah, N., Das, S.K., Das, G., Tarafder, S., Gupta, K.K., and Ghosh, R.N., Investigation on the failure of air compressor. Engineering Failure Analysis, 2009. 17: p. 150-157. [19] Oravec, K. and Vojtko, M., Mechanical Properies of A Pressed Piece En AW 2618a Al-Alloy After Heat Treatment. Materials Engineering, 2009. 16: p. 29-32. [20] Bills, P.J., Introduction to Computed Tomography as an Aid to Forensic Analysis, in Age Estimation Workshop,. 2016, University of Huddersfield, UK: University of Huddersfield, UK. p. 27. [21] Lifton, J.J., Malcolm, A.A., Mcbride, J.W., and Cross, K.J., The Application of Voxel Size Correction in X-ray Computed Tomography for Dimensional Metrology, in International NDT Conference & Exhibition. 2013: Singapore. [22] Alicona. InfiniteFocus Technical Specifications. Alicona That's Metrology n.d [cited 2016 04 October]; Available from:
Depositing User: Md Shams E Tabriz
Date Deposited: 26 May 2017 15:18
Last Modified: 28 Aug 2021 15:58


Downloads per month over past year

Repository Staff Only: item control page

View Item View Item

University of Huddersfield, Queensgate, Huddersfield, HD1 3DH Copyright and Disclaimer All rights reserved ©