To reduce the pressure drop of diesel particulate filter (DPF) as well as improve its collection efficiency. A mathematical model of DPF pressure drop and capture efficiency was established. This research systematically investigates the effects of channels per square inch (CPSI), wall thickness, and carrier ratio on DPF performance through grey relational analysis (GRA) and polynomial approximation algorithm (PAA). The findings reveal that DPF exhibits lower pressure drop and higher collection efficiency in the case where the carrier ratio, wall thickness, and CPSI are within the ranges of 1.40 to 1.53, 9.8 to 10.5 mil, and 200 to 300, respectively. Particularly, at a carrier ratio of 1.52 and a wall thickness of 10.38 mil, the pressure drop reaches a minimum value of 4.23 kPa, with a collection efficiency of 90.28%. Meanwhile, at a carrier ratio of 1.52 and a CPSI of 200, the pressure drop reaches a minimum value of 4.17 kPa, with a collection efficiency of 90.21%. The model expressions for pressure drop and collection efficiency derived from the PAA are: y 1 = 51.19 + 3.815 x 1 − 8.726 x 2 + 3.794 x 1 2 − 1.735 x 1 x 2 + 0.524 x 2 2 , and y 2 = 0.383 + 0.105 x 1 + 0.085 x 2 + 0.032 x 1 2 − 0.016 x 1 x 2 − 0.0032 x 2 2 . The foregoing models exhibit excellent predictive accuracy and goodness of fit for the DPF performance. Under the interactive influence of carrier ratio and wall thickness, the root mean square errors (RMSE) for pressure drop and collection efficiency are 0.0110 and 0.0002, respectively, with corresponding goodness of fit values of 0.9996 and 0.9985. As revealed by the GRA results, wall thickness exerts the most significant impact on DPF performance, presenting a GRG of 0.84 for filtration efficiency and 0.79 for pressure drop. The overall influence on both collection efficiency and pressure drop follows the descending order: wall thickness > carrier ratio > CPSI. This work has important engineering significance for optimizing the DPF capture performance and extending its working time.
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