Advanced Science and Technology Letters

Vol.118 (Mechanical Engineering 2015), pp.59-63

http://dx.doi.org/10.14257/astl.2015.118.12

Flow Analysis of Exhaust Manifolds for Engine

Jae Ung Cho1

1
Division of Mechanical & Automotive Engineering, Kongju National University, 1223-24,
Cheonan Daero, Seobuk-gu, Cheonan-si, Chungnam of Korea 31080, jucho@kongju.ac.kr

Abstract. In the exhaustion manifold, which emits exhaust gas, thermal

deformation by flow occurs due to periodically recurring thermic conditions of
overheat and overcooling time. Therefore, we need to properly understand the
thermal deformation by the flow of high temperature exhaust gas occurring in
the manifold. In this study, two forms of exhaust manifolds used in turbo diesel
engines are analyzed to find out which form shows more efficiency. This
research used ANSYS program for analysis.

Keywords: Exhaust manifold, Flow analysis, High temperature, Thermal

deformation

1 Introduction

Exhaust manifold, which is connected to the cylinder head, emits exhaust gas in the
cylinder. Model 1 in this research is the manifold used in the engine of D2848T, and
model 2 is modeled as the manifold which is often found in heavy equipment vehicles
such as an excavator by using CATIA program. We conducted the ANSYS program
and compared the thermal effects by the flow analyses of the two models and tried to
find out which one is more efficient. If this analysis result is applied in later designs
of manifolds for turbo diesel engines, we expect to develop an exhaust manifold with
the improved the thermal characteristics by flow, durability, and engine
performance[1-5].

2 Model and Analysis

2.1 Model

To investigate about thermal stress by flow and the characteristics of turbo diesel
engine exhaust manifolds, a restriction effect occurring from thermal expansion of the
cylinder head must be considered. The analysis model of exhaust manifold is made by
simplifying the actual model. Exhaust manifold models were made by using CATIA

ISSN: 2287-1233 ASTL

Copyright © 2015 SERSC
Advanced Science and Technology Letters
Vol.118 (Mechanical Engineering 2015)

program. The configuration and mesh of model 1 and model 2 are shown as Fig. 1(a )
and (b). Table 1 shows the numbers of finite elements necessary for analysis. Material
property of the models are AISI 5000 series steel among gray cast iron, and the
property is presented in Table 2.

(a) Model 1 (b) Model 2

Fig. 1 Mesh configuration.

Table 1. Numbers of nodes and elements at models.

Nodes Elements
Model 1 38397 19239
Model 2 43300 21571

Table 2. Material property.

Young's Modulus 2× 105MPa

Poisson's Ratio 0.3
Density 7850kg/m³
Thermal Expension 1.2× 105
Tensile Yield Strength 1070MPa
Compressive Yield Strength 1070MPa
Tensile Ultimate Strength 1170 MPa

2.2 Analysis of Thermal Stress by Flow

When the vehicle runs at the speed of 60km/h, the entrance temperature of the
manifold by flow is 300℃ and its pressure is 5MPa. The exit pressure is 0.65MPa
and pressure ratio is 10. In this experiment, the convection coefficient of heat transfer
is set at and the manifold is exposed to 22℃ of air. We conducted
the analysis by assuming that the average inner temperature of manifold by flow is
139.5℃. For the boundary condition of the model's thermal conduction, 139.5℃ is
given as the average temperature inside the manifold, as can be seen in Fig. 2

60 Copyright © 2015 SERSC

 Advanced Science and Technology Letters
Vol.118 (Mechanical Engineering 2015)

(a) Model 1 (b) Model 2

Fig. 2. Thermal constraint condition by flow.

(a) Model 1 (b) Model 2

Fig. 3. Contour of thermal temperature at steady state by flow.

In Fig.3, the temperature contour of the manifold due to thermal conduction by flow
is provided when the vehicle runs at the speed of 60km/h at the normal state. The
boundary condition of the model's thermal stress analysis by flow is as follows; the
surfaces of the manifold's entrance and exit are fixed, bolt condition is applied where
there is a bolt, the entrance pressure is 5MPa, and the exit pressure is 0.65MPa as
shown by Fig. 4. Fig. 5 shows each model's amount of the stress equivalent stress
caused by heat.

(a) Model 1 (b) Model 2

Fig. 4. Constraint conditions of fixed support, pressure and frictionless support by flow.

Copyright © 2015 SERSC 61

Advanced Science and Technology Letters
Vol.118 (Mechanical Engineering 2015)

(a) Model 1 (b) Model 2

Fig. 5. Contour of equivalent stress by thermal load.

In this research, thermal stress of engine joint parts by flow were analyzed, which
were found to affect the durability of these manifolds. In Fig.5, at the inner entrance
of flange, jointed with the manifold and the entrance through which the exhaust gas of
each engine's cylinder enters, the highest stress level of 1369.1MPa in model 1 and
2520.7MPa in model 2 at the same part was shown.

3 Conclusion

In this research, we obtained the following results through the analysis of thermal
stress by flow of two forms of turbo diesel engine exhaust manifolds.
At the equivalent thermal stress levels of model 1and mode 2, at the inner entrance
of flange, jointed with the manifold and the entrance through which the exhaust gas of
each engine's cylinder enters, the highest stress levels of 1369.1MPa in model 1 and
2520.7MPa in model 2 at the same part was shown.
By flow analysis on thermal stress, model 1 showed thermal stress less than model
2, so we expect that manifold of model 1 will show superior performance than model
2.
If we apply these analysis results to turbo diesel engine manifolds to be designed
later, we expect to develop products with improved the thermal characteristics by
flow, durability, structure, and engine performance.

References

1. Rahim, R., Mamat, R., Taib, M. Y. and Abdullah, A.: A Influence of Fuel Temperature on a
Diesel Engine Performance Operating with Biodiesel Blended. International Journal of
Advanced Science and Technology, vol. 43, pp. 115--126 (2012)
2. Adepoju, G. A. and Komolafe, O.A.: Analysis and Modelling of Static Synchronous
Compensator (STATCOM): A comparison of Power Injection and Current Injection Models
in Power Flow Study. International Journal of Advanced Science and Technology, vol. 36,
pp. 357--384(2011)

62 Copyright © 2015 SERSC

 Advanced Science and Technology Letters
Vol.118 (Mechanical Engineering 2015)

3. Palhade, R. D., Tungikar, V. B., Dhole, G. M., Kherde, S. M.: Transient Thermal
Conduction Analysis of High Voltage Cap and Pin Type Ceramic Disc Insulator
Assembly. International Journal of Advanced Science and Technology, vol. 56, pp.73--
86 (2013)
4. Huang, D. S., Huang, F. C.: Coupled thermo-fluid stress analysis of Kambara Reactor
with various anchors in the stirring of molten iron at extremely high temperatures.
Applied Thermal Engineering, vol. 73, no. 1, pp. 220--226 (2014)
5. Tomas U. G. Jr.: Investigation on the use of Coco Coir Polypropylene as Thermal
Insulator. International Journal of Advanced Science and Technology, vol. 59, pp.13--
26 (2013)

Copyright © 2015 SERSC 63