A computer simulation methodology is developed to model the water quenching process for engine block and cylinder head. The methodology is based on the Eulerian-Eulerian two-fluid method implemented in existing commercial computational fluid dynamics (CFD) software. Due to the complex physics involved in the phase change and mass transfer, one of the prime objectives is to search and evaluate CFD tools that are capable of modeling the water quenching processes. Then the methodology is validated by comparing the CFD result with thermocouple data from lab experiments conducted in a controlled environment. Thorough comparison of results from various quench orientations indicated that the methodology is robust enough to produce reasonable and consistent results. The temperature history obtained by this methodology could be mapped to FEA model to predict residual stress, which in turn can be used to study the durability of the engine components.

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Computer Aided Engineering is an effective tool utilized to drive an exhaust manifold design by early assessment within the engine program development phase. However, in the end, for exhaust manifold design verification, various tests must be performed in engine dynamometer cells under severe operating conditions. The test running durations are up to 2500 hours for the heavy-duty (HD) exhaust manifold. Therefore, the validation tests are expensive and time-consuming. Alternative ways are sought to replace these expensive tests for cost reduction purposes and more efficient dynamometer cells. Thus, the custom test rig is designed and built. This system contains the burner system supplying hot gas at a similar temperature and mass flow ranges with the engine. The drawback of the burner system is, it runs in steady-state mode, so very challenging to replicate the engine's pulsating flow effect exactly. Therefore, with the coupling of Star-CCM+ and Modefrontier, the CAE study is carried out to assess the feasibility of obtaining similar manifold skin temperature distribution in the burner test cell with engine conditions. It is aimed to determine the correct valve opening positions regulating the mass flow rate through the runners. This innovative methodology reduces the trial-and-error count in the experiment phase.

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