A turbocharger is certainly one of the fundamental devices being employed to enhance output power of petrol and/or diesel and is of paramount importance for use in heavy duty diesel engines.This work aims to increase the power of a six-cylinder turbocharged, four stroke, direct injection heavy duty diesel engine via replacing its fitted turbocharger with a properly selected and matched one. The matching criteria and the effect of intercooler presence are studied. A performance prediction model for turbocharged engine is created to investigate the engine-turbocharger matching. To address this, a program code has been upgraded and modified to select the suitable engine turbocharger using FORTRAN PowerStation 5.0 language. The study includes also an experimental part; where three types of turbochargers, (namely HX80, HB3 and HX40) are tested. The P-Ф diagram, the engine performance parameters together with the exhaust and soot emissions are measured and compared for the cases of original and best turbocharger (HX80). The developed computer algorithm appears to provide results that are in good agreement, within acurcey of + 5%, with the measured data; a fact that encourages designers to trustly use it in their selection and matching of a turbocharger to diesel engines.
This paper involves simulation of a 4-stroke direct injection heavy duty diesel engine piston made of aluminum silicon alloy to determine its temperature field, stress distribution and deformation at the conditions of upgrading the engine power from 300 HP to 350 HP. Turbocharger is the way used to enhance the engine power from 300 HP to 350 HP beside improving the fuel injection system. When the engine power is upgraded, high temperature and pressure will be developed because the engine will run at high loads. The piston is subjected to the coupled action of the thermal effect due to the transfer of heat from the head to the body and the mechanical effect represented by the combustion pressure and the inertial load due to the important change of direction of the piston in the cylinder bore. This results in producing stresses in the piston and if these stresses exceed the designed values, the failure of the piston is the result. Finite element analysis (FEA) is considered as one of the best numerical tools to model and analyze the physical systems. The three dimensional piston model was developed in Solid-Works and imported into ANSYS software. Finite element analysis is considered Code for preprocessing, loading and post processing. The simulation parameters used in this paper were combustion pressure, inertial effects and temperature. Diesel RK software is used to simulate the thermal analysis of engine cycle at each case of engine power 300 HP and 350 HP. Also, this model included the effect of the heat flow on the piston to overcome the whole area of the piston is used to illustrate the temperature distribution on the total area of the piston. This area divided into piston surface area and sidle area of piston which included the groves of rings (pressure and oil). The heat transfer coefficient is determined in each area of the piston according to the mechanism of heat transfer. Finally, the results of two different piston conditions are compared with each other. The highest temperature appeared at the combustion chamber side which occurred at the edges of the piston top face in direct contact with the hot gases in the radial. The piston deformation value is within a safe margin and below the gap between the piston and the cylinder bore in case of engine power of 350 HP. The highest calculated value of stresses was below the yield stress of the piston material at elevated temperatures and engine brake power of 350 HP. Hence the piston would withstand the induced stresses during work cycles.
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