An Intake System Optimization of a Heavy Duty DI Diesel Engine Using CFD Analysis

Abstract

As the intake system design is significant for the optimal performance of internal combustion engines, this work aims to optimize the geometry of an intake system in a direct injection (DI) diesel engine. The study concerns the geometry effects of three different intake manifolds mounted consecutively on a fully instrumented, six cylinders, in line, water cooled, 19.1 liters displacement, DI heavy duty diesel engine. A 3D numerical simulation of the turbulent flow through these manifolds is applied. The model is based on solving Navier-Stokes and energy equations in conjunction with the standard K-ε turbulence model and hypothetical boundary conditions using ANSYS- CFX 15. Numerical results of this simulation are presented in the form of flow field velocity as well as pressure field. Optimal design of the intake system is performed and the modeling made it possible to provide a fine knowledge of in-flow structures, in order to examine the adequate manifold. Engine performance characteristics such as brake torque, brake power, thermal efficiency and specific fuel consumption are also carried out to evaluate the effects of the variation in the intake manifold geometry and to validate the optimal design. Simulation and experimental results confirmed the effectiveness of the optimized manifold geometry on the engine performances.