Simulations in the development process

Simulation is a key part of our product development process. With simulation tools, we can model all relevant physics and chemistry in the exhaust gas aftertreatment systems early in the product development phase.
Flow trajectories in EAT system
Thermal expansion induced displacement
Surface temperature and flow trajectories
We can determine a product's material and structural durability in the concept design phase through durability and fatigue analysis. The simulations range from concept designs and pure research work to fine-tuning existing systems in close co-operation with the engine laboratory. We can virtually test a large number of design concepts, easily compare alternative designs and quickly make changes in the design and narrow down the number of suitable design concepts without spending time or money on experimenting.

CFD simulations

Our computational fluid dynamics (CFD) simulation capabilities allow us to analyze and evaluate the exhaust aftertreatment system from layout design to prototypes and all the way to final products. The system operation is simulated in the initial design stages to ensure a viable layout. After this, the system moves into a prototype design which is simulated and verified in the engine laboratory. The CFD simulations go hand in hand with the laboratory tests all the way to the final product design.

During the design process, we study the performance of the exhaust aftertreatment system, which includes:

  • General exhaust gas flow simulations to determine the backpressure and flow characteristics of the system
  • Multiphase simulation with droplet evaporation, chemical reactions and droplet-wall interactions to evaluate SCR performance
  • Heat transfer studies for skin temperature and insulation efficiency
  • Thermal stress simulations to identify the high-stress areas in the system geometry

We are benchmarking the simulation with the manufactured prototypes at every stage of the design process to fine-tune and to improve our simulation methodologies. This way we are able to make reliable simulations and smart design choices for the benefit of our customers.

FEM simulations

The FEM simulations mainly focus on the vibration and durability analyses of the exhaust aftertreatment systems. Similarly to CFD, the system is simulated in the initial design stages to ensure its viability. For the simulations, we measure the accelerations from actual applications and compile a representative test curve. The test curve is then used as a boundary condition in the simulation. If the stresses in the system rise too much, changes need to be done to the mechanical design.  Additionally, we can measure strain and temperatures which can be used to validate the simulations.

  • Vibration analyses are used to evaluate vibration-induced stresses in exhaust aftertreatment
  • Durability analyses use the stresses from the normal vibration analyses to evaluate the product's mechanical ageing
  • Thermal stress analyses are used to find high thermal stresses in the structure and to calculate prestresses for the vibration analyses