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<div class="section abstract"><div class="htmlview paragraph">With the advent of stricter emission norms such as Bharat Stage VI - Phase I and II, the design of the exhaust after treatment system becomes crucial for the internal combustion engine. Inadvertently, the size of the after-treatment system also becomes bigger to cater to the latest emission norms, which leads to increased resistance to the flow of exhaust gases through them. However, the resultant back pressure generated in these devices deteriorates the engine performance. Hence, the onus is on the engine designer to design the after-treatment system and the bracketing concept for mounting in such a way that the engine performance remains intact, and the entire system is packaged within the vehicle boundary conditions. The after-treatment system experiences severe vibrational loads as well as thermal loads. Hence, the designer faces the challenge of carefully designing the system and its brackets to survive the desired engine life and to package the entire system within the vehicle boundaries considering the thermal expansion of the system. Current work depicts the design evolution of the after-treatment system for 2.2-liter, 4-cylinder, high power diesel engine. Initially, commercially available AVL Boost software predicted the exhaust gas state along with the engine performance. With the one-dimensional simulation results and preliminary exhaust system design, a 3D CFD analysis was carried out. This predicted the temperatures at different locations of the computational domain of the after-treatment system. Subsequently, CAE analysis were carried out for modal analysis which predicted the first mode of 189Hz which was 9Hz above the target of 180Hz considering a factor of safety of 1.2. FRF analysis and fatigue analysis (TMF and HCF) were carried out to further predict the stresses on each part of the after-treatment system and to ensure that there were no stress peaks due to resonances. Thus, the exhaust after treatment design evolved in steps to ensure the durability of the exhaust system.</div></div>
<div class="section abstract"><div class="htmlview paragraph">With the advent of stricter emission norms such as Bharat Stage VI - Phase I and II, the design of the exhaust after treatment system becomes crucial for the internal combustion engine. Inadvertently, the size of the after-treatment system also becomes bigger to cater to the latest emission norms, which leads to increased resistance to the flow of exhaust gases through them. However, the resultant back pressure generated in these devices deteriorates the engine performance. Hence, the onus is on the engine designer to design the after-treatment system and the bracketing concept for mounting in such a way that the engine performance remains intact, and the entire system is packaged within the vehicle boundary conditions. The after-treatment system experiences severe vibrational loads as well as thermal loads. Hence, the designer faces the challenge of carefully designing the system and its brackets to survive the desired engine life and to package the entire system within the vehicle boundaries considering the thermal expansion of the system. Current work depicts the design evolution of the after-treatment system for 2.2-liter, 4-cylinder, high power diesel engine. Initially, commercially available AVL Boost software predicted the exhaust gas state along with the engine performance. With the one-dimensional simulation results and preliminary exhaust system design, a 3D CFD analysis was carried out. This predicted the temperatures at different locations of the computational domain of the after-treatment system. Subsequently, CAE analysis were carried out for modal analysis which predicted the first mode of 189Hz which was 9Hz above the target of 180Hz considering a factor of safety of 1.2. FRF analysis and fatigue analysis (TMF and HCF) were carried out to further predict the stresses on each part of the after-treatment system and to ensure that there were no stress peaks due to resonances. Thus, the exhaust after treatment design evolved in steps to ensure the durability of the exhaust system.</div></div>
The last few years have seen an increase in the complexity of emission standards. This has caused OEMs to start using Exhaust Gas Processors (EGP) or Exhaust After Treatment Systems (EATS)in complex integration. These systems are usually mounted on vehicle chassis or engine body with the help of mounting straps or brackets. The arrangement of the system leads to road loads and/or engine vibrations being transferred and causing damage to its components. New BS VI engines need some AT (After treatment) components to be mounted directly on the engine and others to chassis. The components that are directly mounted on engine are called close couple AT system which are subjected to engine harmonic vibrations which falls under forced vibration criteria. Most of the AT system are subjected to random vibrations and industry has a well-defined procedure to address the problem, but for harmonic vibrations there is no specific approach. In order to optimize the structural durability of close couple AT system against HCF (high cycle fatigue) fatigue harmonic vibration, there is a need for well-defined test analysis correlation procedure. The objective of this work is defining and documenting a robust process for design margin through calculation modal scaling and harmonic analysis of close couple AT system through test analysis correlation activity. Analytical, numerical and testing data were compared and conclusions are drawn. More case studies can be added to this work in order to validate the test analysis correlation activity and boost the degree of confidence. Future study may include recording additional failure modes in addition to the harmonic HCF failure mode.
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