Integrated thermal and modal analysis of turbocharger with 3D Printed Prototype

Turbochargers improve engine performance and fuel efficiency by raising air intake pressure, but they encounter issues such as thermal deformation and vibrational instability under high stress. This paper does a combined thermal and modal analysis of a turbocharger system utilizing computational simulations and experimental validation with a 3D-printed prototype. Finite element methods (FEM) evaluate temperature distribution, heat transmission, and thermal loads to detect overheating concerns and critical fatigue zones. Modal analysis assesses vibrational activity, identifying natural frequencies and resonance circumstances that may lead to mechanical failure. The interplay of thermal expansion and vibration is investigated to forecast and reduce failure scenarios.

A 3D-printed prototype is tested in controlled environments to confirm simulations and ensure correct performance predictions. This comprehensive method optimizes turbocharger design to increase longevity, efficiency, and dependability. The findings assist the development of more durable turbochargers that can resist harsh automotive conditions, improving engine performance while lowering maintenance costs. The study emphasizes the need of addressing both thermal and vibrational concerns by combining advanced models and actual prototyping. The findings open the way for future advancements in vehicle engineering, allowing for the development of more durable and high-performance turbocharger systems.

Thermal and modal study were conducted to compare three materials for 3D-printed turbochargers: Silicon Carbide exhibited higher heat resistance (4446.8°C), but Molybdenum had higher thermal conductivity (15440 W/m²) and vibration stability (11.474 Hz). Ni Resist Cast Iron underperformed Molybdenum, making the latter preferable despite Silicon Carbide's thermal advantages, subject to further structural validation.