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quiets the noise of the exhaust by "muffling" the sound waves
created by the opening and closing of the exhaust valves. suppliers. It is also used for ship and power-generation engines,
small two and four stroke engines and racing engines (F1,
GT-SUITE NASCAR, IRL, etc.). It provides the user with many
components to model any advanced concept. Among its
GT-SUITE is an integrated set of computer-aided advantages is its ease of use and its tight integration with the
engineering (CAE) tools developed by Gamma Technologies, rest of GT-SUITE, which give GT-Power a "virtual engine"
Inc. for design and analysis of engines, power trains and perspective [4]. GT-Power environment is shown in Fig. 1. The
vehicles. These tools are contained in a single executable form GT-SUITE environment also provides GT-Power with a proven
which is essential to its use in "Integrated Simulations" [3]. GT- set of high-productivity features for pre- and post-processing,
SUITE comprised of six solvers (GT-Power, GT-Drive, GT- optimization, neural networks and control modeling. Its
Vtrain, GT-Cool, GT-Fuel, and GT-Crank), a model-building usefulness is further enhanced by integration with STAR-CD,
interface (GT-ISE), a powerful post-processing package (GT- Fluent, Simulink and MS/EXCEL [4]. GT-Power is specifically
POST), and a collection of supporting tools. GT-ISE provides designed for both steady state and transient simulations. In
the user with the graphical user interface (GUI) that is used to addition it can be used for analysis of engine/ power train
build models as well as the means to run all GT-SUITE control. GT-Power is available as a standalone tool, or coupled
applications. with GT-Drive, GT-Fuel and GT-Cool as the GT-SUITE / flow
product.
GT-POWER
GT-Power is the industry-standard engine simulation tool,
used by all leading engine and vehicle manufacturers and their
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METHODOLOGY AND SIMULATION SETUP exhaust manifold. The newly designed exhaust manifold is
The methodology used in performing the present work is designed by reducing the angle of bend pipes throughout the
as follows: exhaust gases path from the header up until the outlet of the
1. Engine Selection - The specification of the engine is needed exhaust manifold itself. By reducing the angle of bend pipes,
as the input parameters. the back pressure will be reduced so that the exhaust gases will
2. Exhaust Manifold Measurement – The dimension of the be removed easily from the engine cylinder and thus will give a
existing exhaust manifold has to be measured; several better breathing capability to the engine. In addition, the
dimensions of the newly designed exhaust manifold are diameter of the exhaust manifold pipes are also been enlarged a
proposed by creating several geometry of the exhaust bit to increase the rate of the exhaust gases velocity but must be
manifold; and the geometry of the newly designed exhaust kept within an acceptable range to avoid other unwanted factors
manifold which gives the optimum performance will be to affect the performance.
chosen to be fabricated.
3. GT-Power Modeling – The dimensions for both existing and MODEL SETUP PREPARATION
newly designed exhaust manifold will be modeled in GT- The drag and drop method is used to copy all the listed
Power software for simulation. templates/objects of table - 1 from the example object tree. If
4. GT-Power Simulation – The simulation will be performed the listed template/object is not inside the example object tree,
and the result of both existing and newly designed exhaust it could be copied from template library.
manifold will be compared. Modeling is started from pipe parts of air induction
The engine that has been selected is Proton Iswara 1.5L process. First of all, the pipe from inlet (intake part) to air
gasoline engine [5]. The major area of concern in this work is cleaner will be modeled. Next, throttle part is modeled. It
to focus on the design of exhaust manifold instead of the whole covers from air cleaner intake site to throttle, which is located
components of exhaust system. However, in using the GT- in front of the surge tank. After intake manifold, engine is
Power software, the whole components of exhaust manifold modeled. The modeling will cover the engine head (intake port,
must be included in the simulation and analysis because the intake valve, exhaust port and exhaust valve) including the
exhaust manifold by itself cannot perform its function if there engine cylinder. For the existing exhaust manifold, the pipes
are no combinations of all exhaust components. In this project, are discretized into eight stages for the exhaust manifold. The
the pipes and flowsplits dimensions i.e. length, bend angle, makes it easier to measure the angle of bend, radius of bend and
bend radius, of the existing exhaust manifold of Proton Iswara the length. There are four bend pipes at the first stage, another
are measured and they are being used as input data in the GT- four bend pipes at the second stage, four pipes at the third
Power software. The other parts such as air cleaner, intake stage, two flowsplits at the fourth stage, two bend pipes at the
manifold, fuel system, the engine, catalytic converter, muffler fifth stage, two pipes at the sixth stage, one flowsplit at the
and tailpipe will be kept same to use with the newly designed
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seventh stage and one pipe at the final stage. The attribute meant for Muffler design. Firstly, the muffler would be drawn
folder below (Fig. 2) and connections (Fig. 3 and 4) show the using the available tools inside the software. Then, it will be
path of exhaust manifold path 1 until it enters the catalytic converted into parts which is executable by the GT Power.
converter. There is a special application in GT Power which is
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Figure 4: Catalytic Converter Connections
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Path 2
Path 1 Path 3 Path 4
Figure 7 shows that the back pressure for the existing result of the discretized pipe instead of the overall pipe length
exhaust manifold is higher than the back pressure for the but it is sufficient and clearly shown that reducing the angle of
newly designed exhaust manifold for all values of engine bend pipes will reduce the back pressure which will give a
speeds. This indicates that the designed exhaust manifold is better breathing capability to the engine. Fig. 8 shows the
more efficient in terms of reducing the back pressure in the fabricated exhaust manifold according to design.
exhaust manifold pipe. However, the graph only shows the
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Figure 7: Variation of Back Pressure with Engine Speed
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REFERENCES
CONCLUSION
[1] Ganesan, V., 2004, “Internal Combustion Engines,”
The GT-Power is a very sophisticated simulation software
Second Edition, McGraw Hill.
to be used in designing the automobile exhaust system.
[2] Hillier, V.A.W. and Coombes, P., Hiller’s Fundamentals of
Apart from that, it can also be used to design any other
Motor Vehicle Technology, Nelson Thornes Ltd., United
parts in automobile applications. The newly designed
Kingdom, 2004.
exhaust manifold shows lower back pressure which
[3] Gamma Technologies, GT-Suite, www.gtisoft.com, 2004.
ultimately result better performance of the engine.
[4] Gamma Technologies, GT-Power User’s Manual, GT-
Suite Version 6.1, 2004.
[5] Proton Iswara Features & Specifications, www.eon.com,
2005.
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