Weldment Analysis of a Diesel Engine Exhaust Manifold

2016 ◽  
Author(s):  
Masoud Mojtahed ◽  
Nganh Le ◽  
Jerry Wayne DeSoto
Keyword(s):  
Diesel Engine ◽  
Thermal Loading ◽  
Thermal Stresses ◽  
Engine Performance ◽  
Exhaust Manifold ◽  
Element Analysis ◽  
Performance Requirements ◽  
Pipe Model ◽  
Key Factor ◽  
Double Pipe

The Exhaust Manifold is an increasingly important component of industrial turbocharged diesel engines. It can be a key factor to increase the efficiency of any engine, in this case a power plant diesel engine. Analysis of the various structural and thermal loading of the liquid-cooled manifolds is of vital importance to increase the components efficiency and overall engine performance. In this analysis, problems such as thermal stress issues causing manifold failure are identified and redesigned to meet performance requirements and environmental regulations. These manifolds are of complicated shapes and contain many weld joints to attach several integral parts. The weld regions are identified to be sensitive to thermal stresses and most likely prone to failure. The welds were added to the model in ANSYS® Workbench. Computational Fluid Dynamics (Fluent) and Finite Element Analysis (FEA) were used to analyze the welded model. The main outcome was to understand the welds behavior using the ANSYS software and its powerful tools and to determine whether the areas containing welds are likely to fail under the given conditions. A simple double pipe model was also created and congruently analyzed to validate the results and the techniques used in analyzing the manifold model.

Study on Altitude Adaptability of a Turbocharged Off-Road Diesel Engine

2020 ◽  
Vol 142 (11) ◽  
Author(s):  
Fenlian Huang ◽  
Jilin Lei ◽  
Qianfan Xin
Keyword(s):  
Diesel Engine ◽  
Engine Performance ◽  
Spray Angle ◽  
Fuel Spray ◽  
Intake Manifold ◽  
Bench Test ◽  
Boost Pressure ◽  
Exhaust Manifold ◽  
Power Performance ◽  
Operating Characteristics

Abstract This paper investigates the operating characteristics of an off-road diesel engine to enhance its power performance in plateau. First, the impacts of altitude on the power, fuel economy, and emissions characteristics were analyzed by a bench test. Second, the combustion and overall performance working at different altitudes were studied by three-dimensional numerical simulation, including the relationship between fuel injection parameters and engine performance. The results showed that altitude significantly affects the performance of the off-road diesel engine. As the altitude increased from 0 m to 2000 m, the engine power decreased as much as 4.3%, and the brake-specific fuel consumption (BSFC) increased as much as 6%. At the peak torque condition, the intake manifold boost pressure and the exhaust manifold pressure both reduced with a rise of altitude, while the intake and exhaust manifold temperatures both increased with a rise of altitude. Finally, after comparing the in-cylinder flow conditions and combustion characteristics given by six combustion chamber designs that have different shrinkage ratios, the engine performance at 4000 m altitude with five different fuel spray angles were further optimized. The engine rated power increased by 8.2% when the shrinkage ratio was 7.28% and the fuel spray angle was 150 deg at the 4000 m altitude.

Experimental Investigations of Marine Diesel Engine Performance Against Dynamic Back Pressure at Varying Sea-States due to Underwater Exhaust Systems

2019 ◽  
Author(s):  
Harsh D. Sapra ◽  
Jaswinder Singh ◽  
Chris Dijkstra ◽  
Peter De Vos ◽  
Klaas Visser
Keyword(s):  
Diesel Engine ◽  
Thermal Loading ◽  
Geographical Location ◽  
Engine Performance ◽  
Back Pressure ◽  
Experimental Investigations ◽  
Pressure Waves ◽  
Marine Diesel Engine ◽  
Marine Diesel ◽  
Exhaust Systems

Abstract Underwater exhaust systems are employed on board ships to allow zero direct emissions to the atmosphere with the possibility of drag reduction via exhaust gas lubrication. However, underwater expulsion of exhaust gases imparts high and dynamic back pressure, which can fluctuate in amplitude and time period as a ship operates in varying sea-states depending on its geographical location and weather conditions. Therefore, this research aims to experimentally investigate the performance of a marine diesel engine against varying amplitudes and time periods of dynamic back pressure at different sea-states due to underwater exhaust systems. In this study, a turbocharged, marine diesel engine was tested at different loads along the propeller curve against dynamic back pressure waves produced by controlling an electronic butterfly valve placed in the exhaust line after the turbine outlet. Engine performance was investigated against single and multiple back pressure waves of varying amplitudes and wave periods based on real sea-state conditions and wave data. We found that the adverse effects of dynamic back pressure on engine performance were less severe than those found against static back pressure. Governor control and turbocharger dynamics play an important role in keeping the fuel penalty and thermal loading low against dynamic back pressure. Therefore, a marine engine may be able to handle much higher levels of dynamic back pressures when operating with underwater exhaust systems in higher sea-states.

scholarly journals Design, Optimization and Analysis of a 4-stroke Diesel Engine Piston and Piston rings using Different Materials

2018 ◽  
Vol 10 (01) ◽  
pp. 71-80
Author(s):  
Adhir Tandon
Keyword(s):  
Diesel Engine ◽  
High Performance ◽  
Thermal Stresses ◽  
Structural Deformation ◽  
Piston Rings ◽  
Static Structure ◽  
Element Analysis ◽  
Engine Efficiency ◽  
Steel Piston ◽  
Grey Cast

Modern Automobiles expect a high performance from its engines, which in turn places its requirements on the piston and cylinder components. Hence the piston has to deal with harsher, and tougher thermal and mechanical conditions. It has to undergo higher operating temperatures and pressures as well as higher speeds and at the same time keeping a check on the emissions. Pistons play a key role in increasing engine efficiency by reducing weight and frictional losses. This has made it essential to devise and search unique and creative concepts and materials for Pistons repeatedly, which offers what the engine demands. In this work Aluminium Alloy-4032 has been selected as the piston material of a 4-Stroke Diesel Engine and the piston rings are made of grey cast iron and alloy steel. Piston is designed by analytical methods taking both thermal and structural effects into consideration, then modelled on CATIA V5 and the analysis of structural deformation due to thermal stresses has been done using Finite Element Analysis of Steady State Thermal and its effect on static structure using Analysis software ANSYS

Design, Optimization and Analysis of a 4-stroke Diesel Engine Piston and Piston rings using Different Materials

2018 ◽  
Vol 10 (1) ◽  
Author(s):  
Adhir Tandon
Keyword(s):  
Diesel Engine ◽  
High Performance ◽  
Thermal Stresses ◽  
Structural Deformation ◽  
Piston Rings ◽  
Static Structure ◽  
Element Analysis ◽  
Engine Efficiency ◽  
Steel Piston ◽  
Grey Cast

Modern Automobiles expect a high performance from its engines, which in turn places its requirements on the piston and cylinder components. Hence the piston has to deal with harsher, and tougher thermal and mechanical conditions. It has to undergo higher operating temperatures and pressures as well as higher speeds and at the same time keeping a check on the emissions. Pistons play a key role in increasing engine efficiency by reducing weight and frictional losses. This has made it essential to devise and search unique and creative concepts and materials for Pistons repeatedly, which offers what the engine demands.In this work Aluminium Alloy-4032 has been selected as the piston material of a 4-Stroke Diesel Engine and the piston rings are made of grey cast iron and alloy steel. Piston is designed by analytical methods taking both thermal and structural effects into consideration, then modelled on CATIA V5 and the analysis of structural deformation due to thermal stresses has been done using Finite Element Analysis of Steady State Thermal and its effect on static structure using Analysis software ANSYS.

Thermal Deformation Analysis of Exhaust Manifold for Turbo Diesel Engine

2006 ◽  
Vol 326-328 ◽  
pp. 541-544
Author(s):  
Beom Keun Kim ◽  
Eun Hye Lee ◽  
Jong Sik Park
Keyword(s):  
Diesel Engine ◽  
Cylinder Head ◽  
Thermal Deformation ◽  
Longitudinal Direction ◽  
Deformation Analysis ◽  
Fe Model ◽  
Exhaust Manifold ◽  
Element Analysis ◽  
Engine Exhaust ◽  
Fastener Hole

Thermal deformation of cast iron exhaust manifold for turbo diesel engine is investigated by finite element analysis (FEA). The FE model includes the temperature dependent material properties as well as the interactions between exhaust manifold, cylinder head and fasteners. It also considers the sliding behavior of the flanges of exhaust manifold on cylinder head when either expansion or contraction of the exhaust manifold exceeds the fastener pretension. The result of analysis revealed that remarkable thermal deformation occurred along the longitudinal direction. The amount of deformation was predicted and compared with experimental results. The new design of fastener hole, which allows sliding behavior, is expected to reduce thermal stress in turbo diesel engine exhaust manifold.

Thermo-Mechanical Analysis of the Exhaust Manifold of a High Performance Turbocharged Engine

2018 ◽  
Vol 774 ◽  
pp. 307-312 ◽  
Author(s):  
Mariano Lorenzini ◽  
Matteo Giacopini ◽  
Saverio Giulio Barbieri
Keyword(s):  
Finite Element ◽  
Thermal Fatigue ◽  
Thermal Loading ◽  
Complex Geometry ◽  
Combustion Engine ◽  
Equivalent Plastic Strain ◽  
Operating Conditions ◽  
Exhaust Manifold ◽  
Element Analysis ◽  
Damage Criterion

This contribution presents a methodology for the structural analysis of the exhaust manifold of an internal combustion engine. In particular, the thermal loading and the related thermal fatigue damage mechanism are addressed. The component investigated is a melted exhaust manifold which includes the turbine involute. The complex geometry of the component derives from the project constrains in terms of engine performance and sound targets. Finite Element simulations are performed to obtain a virtual approval of the component geometry, in advance with respect to the component manufacturing. The Finite Element analysis accurately follow the experimental approval procedure which considers different warming and rapid cooling cycles to mimic typical engine operating conditions. Two particular aspects of the developed numerical methodology are described in details: a) the elasto-plastic behaviour of the material at high temperatures; b) a damage criterion for thermal fatigue. Following the Ferrari expertise derived by previous experimental and numerical analysis of other exhaust manifolds, the increase of the equivalent plastic strain registered for a single thermal cycle (delta PEEQ) is firstly adopted as a damage criterion. The methodology reveals itself to be well correlated with the experimental evidences thus limiting the number of tests necessary for the component approval.

Knock criteria for aviation diesel engines

2016 ◽  
Vol 18 (7) ◽  
pp. 752-762 ◽  
Author(s):  
Rik D Meininger ◽  
Chol-Bum M Kweon ◽  
Michael T Szedlmayer ◽  
Khanh Q Dang ◽  
Newman B Jackson ◽  
...  
Keyword(s):  
Diesel Engine ◽  
Diesel Engines ◽  
High Speed ◽  
Thermal Stresses ◽  
Cetane Number ◽  
Pressure Rise ◽  
Maximum Pressure ◽  
Cylinder Wall ◽  
Analysis Model ◽  
Element Analysis

The objective of this study was to develop knock criteria for aviation diesel engines that have experienced a number of malfunctions during flight and ground operation. Aviation diesel engines have been vulnerable to knock because they use cylinder wall coating on the aluminum engine block, instead of using steel liners. This has been a trade-off between reliability and lightweighting. An in-line four-cylinder four-stroke direct-injection high-speed turbocharged aviation diesel engine was tested to characterize its combustion at various ground and flight conditions for several specially formulated Jet A fuels. The main fuel property chosen for this study was cetane number, as it significantly impacts the combustion of the aviation diesel engines. The other fuel properties were maintained within the MIL-DTL-83133 specification. The results showed that lower cetane number fuels showed more knock tendency than higher cetane number fuels for the tested aviation diesel engine. In this study, maximum pressure rise rate, or Rmax, was used as a parameter to define knock criteria for aviation diesel engines. Rmax values larger than 1500 kPa/cad require correction to avoid potential mechanical and thermal stresses on the cylinder wall coating. The finite element analysis model using the experimental data showed similarly high mechanical and thermal stresses on the cylinder wall coating. The developed diesel knock criteria are recommended as one of the ways to prevent hard knock for engine developers to consider when they design or calibrate aviation diesel engines.

CFD Analysis and Experimental Investigation of a Heavy Duty D.I. Diesel Engine Exhaust System

2016 ◽  
Author(s):  
Kareem Emara ◽  
Ahmed Emara ◽  
Elsayed Abdel Razek
Keyword(s):  
Diesel Engine ◽  
Internal Combustion Engines ◽  
Direct Injection ◽  
Engine Performance ◽  
Exhaust System ◽  
Back Pressure ◽  
Optimized Design ◽  
Exhaust Manifold ◽  
Heavy Duty ◽  
Exhaust Gases

Exhaust manifold is one of the most critical components of an internal combustion engines and overall engine performance can be obtained from the proper optimized design of engine inlet and exhaust systems. In this study two exhaust system models with different configuration (the existing as base one and the modified one) are simulated using ANSYS-CFX 15 with the appropriate boundary conditions and fluid properties specified to the system with suitable assumptions. The model is based on solving NAVIERE STOKES and energy equations in conjunction with the standard K-ε turbulence model. The first design is a single pipe receives exhaust gases from all runners and delivers the exhaust gases to turbocharger inlet. But the second design consists of two tubes each of one receives the exhaust gases coming from the three cylinders only. This design makes the intensity of the exhaust pulses of high pressure, which leads to increase the speed of the turbocharger. The uniformity of the flow field and back pressure variations in the two models are discussed in. A decrease in backpressure and increase in velocities are shown using the pressure contour and the velocity contour in the exhaust manifold as well as temperature distribution inside the exhaust manifold system. The best design is also simulated at different engine speed. Finally the modified model with limited back pressure was fabricated and experiments are carried out on a fully instrumented six cylinder in line water cooled heavy duty direct injection diesel engine; (350 hp@2200 rpm and 1400 Nm@1350 rpm).The pressure and temperature are measured at definite points in the exhaust gas manifold. The results obtained by experimental work were compared with the analytic CFD and found to be closely matching with accepted error.

Analysis of a Diesel Engine Exhaust Manifold

2014 ◽  
Author(s):  
Yiran Yang ◽  
Miao He ◽  
Masoud Mojtahed
Keyword(s):  
Diesel Engine ◽  
Stress Distribution ◽  
Operating Conditions ◽  
Exhaust Manifold ◽  
Ansys Software ◽  
Engine Exhaust ◽  
Diesel Engine Exhaust ◽  
Engine Efficiency ◽  
Key Factor ◽  
Coolant Velocity

The exhaust manifold is an essential component of an engine, which has become increasingly important because of innovations in the industry. Thus, the efficiency of an exhaust manifold is a key factor in overall engine efficiency. In operating conditions, there are many factors that may influence the performance of an exhaust manifold, such as temperature, pressure, wall thickness, coolant velocity, etc. A manufacturer of diesel engine’s exhaust manifolds was interested in investigating the performance of its manifolds. This paper describes the method of analysis and results obtained by Fluent and ANSYS software. The purpose of the project is to analyze the stress distribution and locate the areas most prone to failure.

A Marine Turbocharger Compressor Multi-Point 3D Design Optimization Tool

2021 ◽  
Author(s):  
Konstantinos Ntonas ◽  
Nikolaos Aretakis ◽  
Konstantinos Mathioudakis
Keyword(s):  
Diesel Engine ◽  
Design Optimization ◽  
Structural Integrity ◽  
Engine Performance ◽  
Design Tool ◽  
Optimization Process ◽  
3D Design ◽  
Element Analysis ◽  
Turbocharged Diesel Engine ◽  
Compressor Design

Abstract A marine turbocharger 3D compressor design tool, implemented on an existing marine turbocharger retrofit platform is presented. It produces 3D centrifugal compressor geometry for optimal compressor retrofit. It encompasses two modules, allowing the design process to become fully automatic. First, a 1D compressor multi-point design optimization process is carried out, aiming to provide a fast and reliable solution based on Turbocharged diesel Engine range of operation. Structural integrity is ensured by using simplified structural analysis. Dimensionless parameters are used as optimization variables, for a given nominal compressor mass flow and power. Then a CFD compressor multi-point design optimization process is carried out, producing optimized 3D compressor geometry. It complies with the Turbocharged diesel Engine range of operation, while structural integrity is ensured by using Finite Element analysis. A turbocharger compressor design case study is presented. First, a turbocharger 1D compressor design is carried out, aiming to at least reconstituting the original diesel engine performance. This first module provides a reliable compressor initial geometry for the 3D design module. A fully 3D compressor design is then performed, using a CFD-FEA optimization process, in order to provide an improved retrofitting solution. Comparison between the multi-point and the traditional one-point design method, shows that the multi-point method provides a wider SFC reduction in the range that the Diesel engine normally operates.

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