Well, we have had some good comments about the excessive velocity and pressure numbers on the CFD plots. TurboBlueStreak was able to find a better way of testing it with more realistic numbers. We used a Excel sheet for turbo matching to calculate some flow numbers for different boost pressure and RPM. TBS says "all the test were done ignoring atmosphere pressure so inlet and outlet pressures where = to turbo outlet pressure the flow inlet was cubic feet per minute converted to cubic inches per second."
Here is the Excel sheet showing the flow numbers. The test number on the sheet relate to the CFD results below: Click on the picture to enlarge it from my gallery-
Here are the new results as well as some videos
test#1 1.5psi boost 2500 RPM 127 CFM
Test #3 5psi boost 3500RPM 214CFM
Test #7 20 psi boost 5500 RPM 581 CFM
Test #9 20psi boost 7500 RPM 793 CFM
Some videos of test #9
http://album.hybridz.org/data/500/Test_9_velocity.avi
http://album.hybridz.org/data/500/Test_9_velocity_b.avi
http://album.hybridz.org/data/500/Test_9_velocity_c.avi
So now you can see that as the flow and velocity go up, there is some crazy swirling going on in the plenum. It looks like 1 swirl is feeding each bank of runners. It also looks like the runners 1 and 2 are not getting balanced flow. Maybe a baffle inside will help, or maybe something in the plenum to disrupt the vortices.
I hope you find the new information and test data interesting. A big thanks again to TurboBlueStreak for his time in the CFD analysis.
So any new comments? Should I be worried about the results as they are?
Jeff