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.

Increase of the capacity of heavy duty diesel engines is of great interest in the way of power enhancement in many engine applications. Turbocharger is one of the most important ways used to increase the engine specific power. The present study aimed to develop an analytical model to simulate the performance and combustion characteristics of a direct injection diesel engine. This model depends on the basic conservation equations of continuity, momentum and energy as well as equation of state, these equations are solved together numerically by using two steps Lax-Wendroff scheme. To address this, a comprehensive computer “FORTRAN” code was developed and applied to study the performance and combustion characteristics of a six-cylinder, four stroke, direct injection, heavy duty diesel engine as a base engine and when its power upgraded by 15% using a turbocharger. This code is open source, preprocessor is user-friendly and very easy in work and will used at any time. The computed results are compared with the results obtained by applying the engine simulation DIESEL-RK software. But the DIESEL-RK solver may be run under the control of an external code. In that case the interface of the program includes input & output text files. Templates of these files are generated automatically. The developed model provides reasonable estimates and the experimental validation of the model show that an appropriate agreement between mathematical model, DIESEL-RK software, and the real measurements, in addition the capability of the model to predict satisfactorily the performance, and combustion characteristics of the direct injection diesel engine. Simulation study was also performed to compare the turbocharged engine with the naturally aspirated direct injection diesel engine. This study examined the engines for operating parameters like brake power and brake specific fuel consumption over the entire speed range and revealed that turbocharging offers higher brake power and lower brake specific fuel consumption values for most of the operating range. The results indicated that turbocharging offers marginally higher brake thermal efficiency and enhancing the engine performance.

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.