Front. Mech. Eng.
2013, 8(4): 390–400
DOI 10.1007/s11465-013-0278-2
RESEARCH ARTICLE
Lei HUO, Huoxing LIU
Discussion on back-to-back two-stage centrifugal
compressor compact design techniques
© Higher Education Press and Springer-Verlag Berlin Heidelberg 2013
Abstract Design a small flow back-to-back two-stage
centrifugal compressor in the aviation turbocharger, the
compressor is compact structure, small axial length, light
weighted. Stationary parts have a great influence on their
overall performance decline. Therefore, the stationary part
of the back-to-back two-stage centrifugal compressor
should pay full attention to the diffuser, bend, return
vane and volute design. Volute also impact downstream
return vane, making the flow in circumferential direction is
not uniformed, and several blade angle of attack is
drastically changed in downstream of the volute with the
airflow can not be rotated to required angle. Loading of
high-pressure rotor blades change due to non-uniformed of
flow in circumferential direction, which makes individual
blade load distribution changed, and affected blade
passage load decreased to reduce the capability of work,
the tip low speed range increases.
Keywords back-to-back, two-stage, centrifugal compres-
sor, design, Internal flow
1 Introduction
Aeronautical turbocharger is key components in unmanned
aerial vehicle (UAV) program with piston engine power,
which has an important role to improve the flight altitude
of the UAV and restore the power piston engine in high-
altitude environment [1,2]. Aeronautical turbocharger
requires light weight, small size, reliability, high efficiency,
and with specific requirements to the centrifugal compres-
sor, high pressure ratio, light weight, small size, high
efficiency. Foreign advanced turbochargers are often to
Received July 27, 2013; accepted August 1, 2013
✉
Lei HUO ( ), Huoxing LIU
School of Jet Propulsion, Beihang University, Beijing 100191, China
E-mail: hawk@sjp.buaa.edu.cn
adopt a two-staged centrifugal compressor, TMS Company
developed two-staged turbocharger makes ‘Predator’ UAV
flight altitude of 15800 m, the improved Predator named
Oster2uses a two-staged turbocharger, could make altitude
of more than 15500 m [3]. Two-stage centrifugal com-
pressor has advantages of simple structure, lower manu-
facturing costs and wide scope of work, etc. It has been
widely adopted in advanced aero turbo mechanism. Such
as the US T800-LHT-800, MTR390 developed by
England/Germany/France, and Ardiden which is consid-
ered to be the most advanced turboshaft engines by
Turbomeca, these all adopted a two-stage centrifugal
compressor. Conventional two-staged centrifugal com-
pressor composed by the low-pressure compressor I
diffuser, II bend, III return vane, IV high-pressure
compressor, V diffuser, VI volute, VII several parts serial
formed, for Conventional two-stage centrifugal compres-
sor design, calculation, and test, many scholars have
conducted numerous studies [4–8]. The back-to-back two-
staged centrifugal compressor compared with conventional
compressor is the contrast the direction of the high-
pressure compressor, and the low-pressure compressor
back to back arrangement, as shown in Fig. 1. The back-to-
back two-stage centrifugal compressor is significantly with
compact structure than the conventional form, shorter axial
length, high- and low-pressure compressors can be
processed on a roulette, which are conducive to the
installation and reduce weight. But this makes the design
more difficult, more complex structure and process.
Honeywell designed a turbocharger on the use of this
back-to-back two-stage centrifugal compressor superchar-
ging system [9]. And so far, no this form of two-stage
centrifugal compressor in China, so it is necessary to study
the back-to-back two-stage centrifugal compressor design
technologies and internal flow. This article designs a back-
to-back two-stage centrifugal compressor, and using
numerical simulation to discuss the compact design of
the back-to-back two-stage centrifugal compressor tech-
nology and internal flow.
 Lei HUO et al. Discussion on back-to-back two-stage centrifugal compressor compact design techniques 391

Fig. 1 Section sketch map of conventional and back-to-back two-staged centrifugal compressor. (a) Conventional; (b) back to back

2 Design methods and design parameters

In order to meet the performance requirements of the
aeronautical turbochargers under the harsh conditions, the
design environment as altitude of 10000 m, to determine
the two-stage centrifugal compressor design point para-
meters is as Table 1 below. In the case of the high- and low-
pressure centrifugal compressor is coaxial, specific speed
of high- and low-pressure centrifugal compressor should
be considered within a reasonable range. The two-stage
centrifugal compressor power is equiponderance allocated,
thereby determining the low and high-pressure centrifugal
compressor pressure ratio.
Fig. 2 Geometric model of back-to-back two-stage centrifugal
Table 1 Design parameter compressor
Parameter Value
Altitude /m 10000 of the mainstream and secondary flow region in order to
Inlet pressure /Pa 26500 describe the to complex export flow state.
Inlet temperature /K 223.3
The meridional channel shape of the centrifugal
compressor impacts a lot of centrifugal compressor
Total pressure ratio 5.0
performance, the design using Bezier curves to build,
Lp pressure ratio 2.52 adjust the compressor meridional channel, iteration
Hp pressure ratio 1.98 meridional channel shape as shown in Fig. 3. Blade
Flow mass /(kg$s ) –1
0.1 angle distribution is one of the key factors to determine the
Efficiency 0.75
blade load distribution, unreasonable blade load distribu-
tion will lead to the blade surface boundary layer
Shaft speed /(r$min–1) 90000
thickening or separation occurs in advance, resulting in
the deterioration of compressor performance. Blade angle
distribution in this article shown in Fig. 4, blade angle is
Back-to-back two-stage centrifugal compressor in this gradually reduced from leading edge to 60% blade chord at
article include these components: the low-pressure cen- the hub, and thereafter gradually increases from 60% blade
trifugal compressor rotor blades, the low-pressure leafless chord, at the outlet of the impeller, low-pressure rotor
diffuser, bend, return vane, the high-pressure centrifugal outlet angle is 45°, high-pressure rotor outlet angle is 40°,
compressor rotor blades, the high-pressure leafless diffu- low-pressure rotor outlet angle is lager because low-
ser, high-pressure exhaust volute. The geometric model is pressure compressor is connected to bend and return vane,
shown in Fig. 2. need to turn the tangential flow to positive to improve the
Centrifugal compressor design using commercial design high-pressure inlet condition, and the high-pressure
software Concepts NREC to calculate the performance compressor connect to export volute, the larger of
prediction, the model is based on the phenomenon of rotor tangential velocity airflow, the better to reduce volute
blades outlet trail track, dividing rotor export into two areas loss. Before 40% blade chord at the hub, the blade angle
392 Front. Mech. Eng. 2013, 8(4): 390–400

Fig. 3 Meridional contours of centrifugal compressor. (a) Low pressure compressor; (b) high pressure compressor

Fig. 4 Blade angle distribution of centrifugal compressor. (a) Low-pressure compressor; (b) high-pressure compressor

gradually reduced, blade angle almost no change at 40%–
90% blade chord, blade angle appreciably increase after
90% blade chord, it will be equal to hub blade angle at the
outlet.
Centrifugal compressor blade thickness distribution
impacts a lot to the structural strength of the compressor
impeller, for transonic centrifugal compressor, reduce the
thickness of the blade leading edge helps to improve the
aerodynamic performance. Under the premise of maximize
compressor performance and meet current processing
technology, in this paper, the design of the blade leading
edge shroud thickness is 0.7 mm, leading edge hub
thickness is 1.4 mm; trailing edge shroud thickness is
0.8 mm, trailing edge hub thickness is 1.2 mm. Figure 5
shows the thickness distribution of compressor blade.
Using a diffuser designed with convergence for both
sides of vaneless diffusers in this paper, pressure outlet
radius and inlet radius ratio is 1.3. This kind of diffuser
can be in the form of control flow separation, helps to
reduce loss. The return vane could turned the high-speed
tangential velocity airflow to positive which make
the high-pressure compressor works normally, in this
paper, the inlet return vane blade angle designs as
50°, outlet angle is 0°. Basic geometrical parameter of
back-to-back two-stage centrifugal compressor shows as
Table 2.
 Lei HUO et al. Discussion on back-to-back two-stage centrifugal compressor compact design techniques 393

Fig. 5 Thickness distribution of compressor blade. (a) Low-pressure compressor; (b) high-pressure compressor

Table 2 Basic geometrical parameter of centrifugal compressor (mm)

Low pressure High pressure Return vane
Blade hub inlet radius /mm 7.8 6.1 53.2
Blade shroud inlet radius /mm 25.9 20.4 53.2
Blade outlet radius /mm 40.9 35.4 25
Blade axial length /mm 32.7 29.2 4.6
Number of blade 6 6 19
Inlet hub blade angle /(° ) 25 23 50
Inlet shroud blade angle /(° ) 56 54 50
Outlet blade angle /(° ) 45 40 0
Outlet impeller height /mm 4.9 5.4 5.5
Diffuser outlet radius /mm 53.2 46
Diffuser outlet width /mm 4.2 4.6

3 Numerical simulation method is 1950000, volute grid nodes is 1500000, total 6680000.
Calculation grid nodes sketch map is as shown in Fig. 6.
The numerical calculation in this paper using the The inlet total pressure is 26500 Pa, temperature
commercial software CFX, numerical methods using the
time pursuit of finite volume method, spatial discretization
using second-order upwind scheme, time discretization
using second-order differential Euler scheme, using k-e
turbulence model, using optimized wall functions in the
near-wall region, highly adaptive to grid of near-wall
region.
Calculate examples in this paper use the grid nodes
structure in high- and low-pressure centrifugal compressor
rotor blade, diffuser and the return vane, including low-
pressure rotor blades grid nodes 890000, high-pressure
rotor blade grid nodes 790000, return vane grid nodes
1550000, spanwise rotor blades tip gap 5 grid nodes. Bend Fig. 6 Calculation grid nodes sketch map
and volute use unstructured grid nodes, grid nodes of bend
394 Front. Mech. Eng. 2013, 8(4): 390–400

Fig. 7 Characteristics of back-to-back two-stage centrifugal compressor at Design speed condition

223.3 K, axial inlet flow, outlet pressure is average value of
Static pressure. In the calculate, the interface of rotor and
static use the mix interface method, but at the interface of
high-pressure outlet and volute inlet use the freeze rotor
method due to the non-uniform circumferential geometry
of volute.
4 Results and analysis
The calculation results get the characteristics of back-to-
back two-stage centrifugal compressor at Design speed
condition, and the characteristic curve of pressure ratio
according to flow mass, efficiency according to flow mass,
as Fig. 7. Maximum efficiency point is 0.751, pressure
ratio is 4.98, meet the design requirements.
Specific analysis of the flow of those design points is as
below. Table 3 shows the pressure ratio and efficiency of
the different components. We can see that the two
centrifugal compressor efficiencies are not low. The low-
pressure centrifugal compressor efficiency is 0.849, high-
pressure centrifugal compressor efficiency reached 0.868,
but the overall performance of the whole machine is not
high, isentropic efficiency decreased by 10% compare with
the single-stage centrifugal compressor. This indicates
there is great loss in those stationary components as bend,
return vane and volute which impact a lot on the overall
performance.
Figure 8 shows the distribution of outlet absolute flow
angle of low-pressure centrifugal compressor rotor blades
along the spanwise, within 60% of spanwise, the absolute
flow angle basically remained between 40° and 43°, above
60% spanwise, the absolute flow angle decreased, back
flow emerged at the top of the blade, which is caused by
low velocity zone existed at the top of blade. The absolute
flow angle along spanwise is in a great difference, this kind
of flow status will affect diffuser performance adversely.
Figure 9 shows the distribution of outlet absolute flow
angle of low-pressure centrifugal compressor vaneless
diffuser along the spanwise, compared with the rotor
outlet, the absolute flow angle becomes smaller, and the
flow happen mix along the spanwise of diffuser. The
distribution of absolute flow angle is large in the middle
and small at both sides.
Figure 10 shows the distribution of outlet absolute flow

Table 3 Pressure ratio and efficiency of the different components

Part name Pressure ratio Efficiency
whole machine 4.98 0.751
Lp rotor + Vaneless diffuser + Bend +
2.56 0.739
Return vane
Lp rotor + Vaneless diffuser + Bend 2.68 0.772
Lp rotor + Vaneless diffuser 2.90 0.849
Hp rotor + Vaneless diffuser + Volute 1.94 0.834
Hp rotor + Vaneless diffuser 2.05 0.868
Fig. 8 Outlet absolute flow angle of lp rotor blades
 Lei HUO et al. Discussion on back-to-back two-stage centrifugal compressor compact design techniques
Fig. 9 Outlet absolute flow angle of lp vaneless diffuser
Fig. 10 Outlet absolute flow angle of bend
angle along the bend spanwise, the flow continue mixing
after the bend, slight difference between the absolute flow
angle in most regions of the main flow. Figure 11 shows the
distribution of outlet absolute flow angle along the return
vane spanwise, the flow after reflux blade, the absolute
flow angle should be close to 0° at the ideal state, however,
from Fig. 11 it is obviously to find the gap of the flow angle
along spanwise, thus lead to asymmetrically distribution of
absolute flow angle along the spanwise at inlet of the high-
pressure impeller. This phenomenon may be adversely
affected the performance and stability of the high-pressure
compressor, this may cause by unreasonable design of the
return vane. The current return vane design is two-
dimensional shapes, if use three-dimensional return vane
design, may improve the velocity distribution form at inlet
of high-pressure centrifugal compressor.
Figure 12 shows the absolute flow angle distribution at
395
Fig. 11 Outlet absolute flow angle of return vane
Fig. 12 Outlet absolute flow angle of hp rotor blades
outlet of high-pressure centrifugal compressor rotor blades
along the spanwise, within 70% of spanwise, the absolute
flow angle remains substantially at 40°, above 70%
spanwise, the absolute flow angel decrease, and there is
back flow generated at the top of the blade, it is a large
difference of absolute flow angle along the spanwise.
Figure 13 shows the outlet absolute flow angle distribution
of high-pressure centrifugal compressor vaneless diffuser
along the spanwise, after flow mix in the diffuser, little
difference of the absolute flow angle in most regions.
Figure 14 shows a load distribution at different blade
height of No. 2 and No. 5 low-pressure rotor, blade
position shown in Fig. 14(a), as can be seen from the
figure, caused by the potential interaction impact of the
high pressure outlet volute in downstream bend, load
distribution have changed on different blades, at pressure
surface, chord length from 80% to the trailing edge, blade
396 Front. Mech. Eng. 2013, 8(4): 390–400

pressure move up on No. 5 main blade and splitter blade,

and at the suction surface, no big change on main blade
load while pressure move up on splitter blade. This will
have an impact on the flow of blade passage.
Figure 15 shows the relative Mach number distribution
at different blade height surfaces of low-pressure rotor.
Internal flow in low-pressure centrifugal compressor is not
uniform in the circumferential direction, which is caused
by potential interaction of high-pressure outlet volute in
downstream bend. Take No. 2 and No. 5 blade for instance,
potential interaction of volute obviously impact on No. 5
blade passage flow. In three sections can be seen in No. 5
blade passage, low velocity zone range is greater bringing
the loss increases.
In back-to-back two-stage centrifugal compressor, due
to the special structure of the form, high-pressure
Fig. 13 Outlet absolute flow angle of hp vaneless diffuser centrifugal compressor outlet volute have to go through

Fig. 14 Load distribution at different blade height surfaces of low-pressure rotor.

(a) Blade position; (b) near hub; (c) mid-span; (d) near shroud
 Lei HUO et al. Discussion on back-to-back two-stage centrifugal compressor compact design techniques
Fig. 15 Relative Mach number distribution at different blade
height surfaces of low-pressure rotor. (a) Near hub; (b) mid-span;
(c) near shroud
397
the bend, it will affect the flow flowing through bend, thus
cause inlet of return vane circumferential distribution is not
uniformly. Figure 16 shows the static pressure coefficient
distribution at different blade height surfaces of No. 1,
No. 9, No. 11 return vane, can be seen from figure that the
No. 9 and No. 11 return vane are impacted a lot after the
high-pressure outlet volute, No. 1 return vane due to away
from the high-pressure outlet volute get less affection.
No. 9 return vane has obvious positive angle of attack,
leading edge of the blade load is larger, while No. 11 return
vane has obvious negative angle of attack, entire blade load
apparently smaller than the No. 9 return vane. Basically the
same blade loading at the near hub and mid-span surfaces
in spanwise direction, at the trailing edge, the pressure
obvious decline in near shroud surfaces. This is because
flow of near shroud side blade exit turned to axial, result in
flow acceleration and leads to pressure decreased.
Figure 17 shows the distribution of return vane Mach
number, static pressure and stream line at 10% return vane,
can be seen that the flow of return vane in the
circumferential direction is not uniform. The return vane
blade away from the volute, for example the No. 1 blade is
less affected with an ideal flow status; The return vane
blade in the high-pressure outlet volute downstream, for
example the No. 9 and No. 11 return vane are impacted
greater, No. 9 blade has obvious positive angle of attack,
No. 11 blade has obvious negative angle of attack, blade
passage flow is relatively poor, so that the airflow can not
be rotated to desired angle, thus will affect the inlet flow of
high-pressure compressor. If consider to adjust the design
of volute downstream return vane blade angle, reduce the
angle of attack, may reduce flow loss in the return vane,
and to improve the high-pressure compressor inlet
conditions.
Non-uniformed circumferential flow distribution of
high-pressure rotor blades will impact on the flow of the
high-pressure rotor blades. Figure 18 shows a load
distribution at different blade height surfaces of No. 3
and No. 6 high-pressure rotor, blade position shown in
Fig. 18(a). As shown, in the position of near hub, the blade
pressure surface load substantially the same, but very
different load distribution of the suction surface; In the
position of mid-span and near shroud, the load changes at
both suction and pressure surfaces, by contrast, the load
distribution difference of the suction surface side of is
greater. No. 6 blade impact by non-uniformed flow, the
load obvious decreased which leads to lower work capacity
in blade passage.
Figure 19 shows the relative Mach number distribution
at different blade height surfaces of high-pressure rotor,
inlet flow non-uniform flow impact internal non-uniform at
the circumferential direction in the high-pressure rotor.
Take No. 3 and No. 6 blade for instance, No. 6 blades is
affected result in the blade load changes , the range of low
velocity zone become larger and gradually increases from
hub to shroud by the impact.
398 Front. Mech. Eng. 2013, 8(4): 390–400

Fig. 16 Static pressure coefficient distribution at different blade height surfaces of return vane.
(a) Blade position; (b) near hub; (c) mid-span; (d) near shroud

Fig. 17 Flow distribution 10% of the blade height position return vane.
(a) Mach number distribution; (b) static pressure and stream line distribution
 Lei HUO et al. Discussion on back-to-back two-stage centrifugal compressor compact design techniques 399

Fig. 18 Load distribution at different blade height surfaces of high-pressure rotor.

(a) Blade position; (b) near hub; (c) mid-span; (d) near shroud

5 Conclusions should pay full attention to the diffuser, bend, return

1) Design a small flow back-to-back two-stage centri-
fugal compressor in the aviation turbocharger, the
compressor is compact structure, small axial length, light
weighted. A three-dimensional numerical simulation on
the design of the back-to-back two-stage centrifugal
compressor, the calculation results show that the two-
stage centrifugal compressor total pressure ratio of 4.98,
the maximum efficiency is 0.751, meet the design
requirements.
2) Stationary parts of the back-to-back two-stage
centrifugal compressor have a great influence on their
overall performance decline. Therefore, the stationary part
of the back-to-back two-stage centrifugal compressor
vane and volute design.
3) High-pressure outlet volute potential interaction in the
bend lead to individually blade loading distribution change
in low-pressure rotor, making the tip low velocity zone
increases. Volute also impact downstream return vane,
making the flow in circumferential direction is not
uniformed, and several blade angle of attack is drastically
changed in downstream of the volute with the airflow can
not be rotated to required angle.
4) Loading of high-pressure rotor blades change due
to non-uniformed of flow in circumferential direction,
which makes individual blade load distribution
changed, and affected blade passage load decreased to
reduce the capability of work, the tip low speed range
increases.
400 Front. Mech. Eng. 2013, 8(4): 390–400

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Fig. 19 Relative Mach number distribution at different blade

height surfaces of high pressure rotor.
(a) Near hub; (b) mid-span; (c) near shroud