Liquid-cooled exhaust manifolds are widely used in turbocharged diesel engines. The large temperature gradient in the overall manifold can cause remarkable thermal stress. The objective of the project is to optimize the operation condition and modify the current design in order to prevent high thermal stress and to extend the lifespan of the manifold. To achieve the objective, the combination between computational fluid dynamics (CFD) with finite element (FE) is introduced. First, CFD analysis is conducted to obtain temperature distribution, providing conditions of the thermomechanical loading on the FE mesh. Next, FE analysis is carried out to determine the thermal stress. The interpolation of the temperature data from CFD to FE is done by binary space partitioning tree algorithm. To accurately quantify the thermal stress, nonlinear material behavior is considered. Based on stresses and strains, the fatigue life can be estimated. The CFD results are compared with that of the number of transfer units’ method and are further verified with industrial experiment data. All these comparisons indicate that the present investigation reasonably predicts the thermal stress behavior. Based on the results, recommendations are given to optimize the manifold design and operation.
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e-mail: dfu@purdue.edu
e-mail: huangdui@gmail.com
e-mail: ahmedyounes@yahoo.com
e-mail: schreiberc@msn.com
e-mail: wangx@calumet.purdue.edu
e-mail: qzhou@calumet.purdue.edu
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September 2009
Research Papers
Numerical Simulation of Thermal Stress for a Liquid-Cooled Exhaust Manifold
Dong Fu,
Dong Fu
Department of Mechanical Engineering,
e-mail: dfu@purdue.edu
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323
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Dui Huang,
Dui Huang
Department of Mechanical Engineering,
e-mail: huangdui@gmail.com
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323
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Ahmed Juma,
Ahmed Juma
Department of Mechanical Engineering,
e-mail: ahmedyounes@yahoo.com
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323
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Curtis M. Schreiber,
Curtis M. Schreiber
Department of Mechanical Engineering,
e-mail: schreiberc@msn.com
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323
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Xiuling Wang,
Xiuling Wang
Department of Mechanical Engineering,
e-mail: wangx@calumet.purdue.edu
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323
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Chenn Q. Zhou
Chenn Q. Zhou
Department of Mechanical Engineering,
e-mail: qzhou@calumet.purdue.edu
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323
Search for other works by this author on:
Dong Fu
Department of Mechanical Engineering,
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323e-mail: dfu@purdue.edu
Dui Huang
Department of Mechanical Engineering,
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323e-mail: huangdui@gmail.com
Ahmed Juma
Department of Mechanical Engineering,
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323e-mail: ahmedyounes@yahoo.com
Curtis M. Schreiber
Department of Mechanical Engineering,
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323e-mail: schreiberc@msn.com
Xiuling Wang
Department of Mechanical Engineering,
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323e-mail: wangx@calumet.purdue.edu
Chenn Q. Zhou
Department of Mechanical Engineering,
Purdue University Calumet
, 2200 169th Street, Hammond, IN 46323e-mail: qzhou@calumet.purdue.edu
J. Thermal Sci. Eng. Appl. Sep 2009, 1(3): 031010 (10 pages)
Published Online: April 23, 2010
Article history
Received:
January 25, 2009
Revised:
November 5, 2009
Online:
April 23, 2010
Published:
April 23, 2010
Citation
Fu, D., Huang, D., Juma, A., Schreiber, C. M., Wang, X., and Zhou, C. Q. (April 23, 2010). "Numerical Simulation of Thermal Stress for a Liquid-Cooled Exhaust Manifold." ASME. J. Thermal Sci. Eng. Appl. September 2009; 1(3): 031010. https://doi.org/10.1115/1.4001258
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