Catalytic Converter Design, Development & Optimisation using Computational Analysis and Engineering

Computational Analysis and Engineering using P-Cat, WAVE, HeatCad, Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) are sequentially applied to design, develop, and optimize catalytic converter. P-Cat is used to estimate back pressure due to substrates, end cones, and inlet/outlet pipes. WAVE simulation is used to predict the exhaust system back pressure from the engine headface to tail pipe to estimate engine performance. Heatcad, a transient heat transfer analysis is used to simulate the temperature response in the exhaust system to locate the catalytic converter to achieve maximum performance. Heatcad analysis provides the easy way to identify thermal management issues and to design and optimize the runner lengths, material thicknesses of the manifold and downpipes. Computational Fluid Dynamics (CFD) analysis, a powerful means of simulating complex fluid flow situations in the exhaust system, is used to design the converter inlet, outlet cones and the downpipes to obtain uniform exhaust gas flow to achieve maximum converter performance and reduce mat erosion. The uniformity index, velocity index (eccentricity) and pressure drop index predicted are used to optimize the geometry and orientation of the converter components. CFD analysis using heat transfer analysis with chemical reaction is used to identify and optimize insulation mounting material to achieve the targeted converter external shell skin temperature. Finite Element Analysis (FEA) is used to predict structural mechanics and structural dynamics of the full exhaust system to give insight about the thermal fatigueness of the converter assembly. Heat transfer analysis performed with thermal, mechanical and road load conditions is used to predict the static and vibrational stresses of the converter components. It also provides information to design the converter shell structure, cone geometry and material selection. FEA analysis using Explicit code is used to simulate the converter assembly process and to optimize manufacturing tool geometry.