Turbocharger Turbine Housing Segmentation for Casting Formability
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Solution Overview
Problem
Downsizing turbochargers poses challenges in forming the inner wall shape of the turbine housing, particularly in the throat portion of the scroll flow passage, which has a smaller width, leading to decreased formability and feasibility of the core.
Innovation Solution
A turbine housing configuration where the throat forming portion is a separate piece from the main housing, forming the hub-side and shroud-side wall surfaces of the throat portion, and a heat shield portion with interposed gaps between heat-shielding plates to suppress heat radiation, enhancing formability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the turbocharger is downsized, then the size of the turbocharger is reduced, but the formability of the inner wall shape of the turbine housing decreases
Solution Approach 1:
The turbine housing is divided into two separate parts: the main turbine housing and the throat forming portion. The throat forming portion is provided as a separate piece that can be attached to the turbine housing. This segmentation allows the complex throat portion with small axial width to be formed independently, improving core formability during casting while enabling overall turbocharger downsizing.
2Volume of moving object
If the throat portion width is reduced for downsizing, then the turbocharger size is reduced, but the feasibility of the core for casting decreases
Solution Approach 1:
The throat forming portion is separated from the main turbine housing and provided as an independent component. This allows the throat portion to be formed with appropriate dimensions for core feasibility while the overall turbocharger size is reduced. The separate throat forming portion can be designed with optimal geometry for casting core formation.
3Ease of manufacture
If the throat forming portion is made as a separate piece, then the formability of the inner wall shape is improved, but the device complexity increases
Solution Approach 1:
The turbine housing is segmented into the main housing and the throat forming portion. While this increases the number of parts, it significantly improves manufacturability by enabling core formation for the complex throat geometry. The separate throat forming portion can be manufactured independently and attached to the main housing, facilitating mass production and quality control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates the formation of the inner wall shape during casting, improves formability, and reduces heat radiation, thereby enhancing the turbocharger's efficiency and durability.
Implementation Method 1
a heat shield portion positioned on an opposite side of the outlet portion in an axial direction across at least one of the turbine impeller or a scroll flow passage communicating with the turbine impeller
Data Source
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AI summary
A turbine includes a turbine impeller, a turbine housing disposed so as to cover the turbine impeller and internally forming a scroll flow passage through which an exhaust gas flows, and a throat forming portion which is provided as a separate piece from the turbine housing. The throat forming portion is disposed to face a section of the turbine housing and forms a hub-side wall surface of a throat portion of the scroll flow passage in an axial direction, the section forming a shroud-side wall surface of the throat portion.