Numerical Simulation for Exhaust Manifold Based on the Serial Coupling of STAR-CCM+ and ABAQUS

Zhi-En Liu,Fu-Wu Yan,Xue-Ni Li,Chao Wang,Xian-Jun Hou

doi:10.19026/rjaset.6.3608

Abstract

This study aims to realize the serial coupling of STAR-CCM+6.04 and ABAQUS 6.11-1 and provide boundary conditions for the thermal fatigue analysis. To predict the thermal fatigue life of the internal combustion engine exhaust manifold effectively, the transient heat-transfer process between exhaust gases and exhaust manifolds should be reflected accurately. The transient fluid-solid-thermal coupling simulation on the exhaust manifold is carried out by using serial coupling method. The research of dealing with the problems of transient temperature loading, the mesh generating and the interface temperature interpolation of fluid and solid are conducted in the process of numerical simulation. The goal of bidirectional fluid and solid coupling simulation between the CFD software STAR-CCM+ and the FEA software ABAQUS is achieved and the transient temperature and thermal stress distribution are obtained. Comparison with the steady analysis results shows that it's a necessary and effective way of conducting transient analysis.

Highlights

Exhaust manifolds are the main heated parts of internal combustion engine which connect with the cylinder head directly
The phenomenon of exhaust manifold fatigue rupture often occurs when the internal engine durability tests are conducted owing to the severe work environment such as the heavy thermal load, high thermal stress, high frequency of heat cycle shock
Other researchers mainly adopt reverse algorithm to study the coupling heat transfer of cylinder head, piston, etc.: measured several key points’ temperature, adjusted the thermal boundary conditions to make the calculated value correspond with the measured value

Summary

Introduction

Exhaust manifolds are the main heated parts of internal combustion engine which connect with the cylinder head directly. The phenomenon of exhaust manifold fatigue rupture often occurs when the internal engine durability tests are conducted owing to the severe work environment such as the heavy thermal load, high thermal stress, high frequency of heat cycle shock. To predict the thermal fatigue life of exhaust manifolds effectively, it’s necessary to make the transient heat coupling analysis of fluid and structure, calculate the transient fluctuation situation of temperature and thermal stress, find the weak place of the structure so as to provide references for the improvement of manifolds’ design and supply thermal boundary conditions for the analysis of thermal fatigue. Other researchers mainly adopt reverse algorithm to study the coupling heat transfer of cylinder head, piston, etc.: measured several key points’ temperature, adjusted the thermal boundary conditions to make the calculated value correspond with the measured value. Reverse algorithm is based on the temperature measurements, can only improve the existing engines, can’t provide guidance for the new design

Objectives

Methods

Conclusion