Job description

The CAE-engines department is responsible for creation and validation of models that can describe and predict the behaviour of the new and current engines. Due to more increasing requirements on emissions modern diesel engines have become complex systems. These emission legislations cause the need to add additional sub-systems to the base engine. All of these systems and sub-systems with pipes, lines and wiring need to be mounted to the base engine. Some of these currently use brackets or studs. To ensure the lifetime performance of the engine all these systems and subsystems need to be checked on their endurance life. 

In a truck diesel engine, an Exhaust Gas Recirculation (EGR) cooler is used to reduce harmful emissions and improve engine efficiency. The EGR system recirculates a portion of the exhaust gases back into the engine’s intake air. Because these exhaust gases are hot, the EGR cooler lowers their temperature before they enter the engine. Cooler exhaust gases help reduce the formation of nitrogen oxides (NOx), which are harmful pollutants. By using an EGR cooler, the engine can meet emission standards while maintaining performance and fuel efficiency.

For the system of the EGR cooler now interest has been raised to investigate if this system can be optimized while remaining similar lifetime performance. The system performance in this case should remain equal while having a weight advantage over the current system. The final design should be validated with Finite Element Method (FEM) simulations for all known loadcases.
This design study will use a lot of Design For Six Sigma (DFSS) tools to come to a well chosen final design.

• Analytical calculations as introduction to FEM.
• Numerical modelling introduction.
• Benchmarking design solutions
• Design study using DFSS tool.
• Final design choice and creation
• Final design validation 
• Final design evaluation