Computer-Aided Engineering Approach to Optimize Hydroformed Exhaust Gas Recirculation Tube under Thermal Load

This study emphasizes the importance of computer-aided engineering (CAE) approach in optimizing exhaust gas recirculation (EGR) tube under thermal load. With exhaust gases generating high temperatures, the EGR tube experiences increased stress and strain, posing challenges to its structural integrity. Moreover, the cyclic heating and cooling cycles of the engine imposes thermal fatigue, further compromising the tube’s performance over time. To address these concerns, the paper introduces a comprehensive CAE methodology for conducting factor of safety analysis. The nonlinear thermal analysis is performed on the assembly as due to high temperatures the stresses cross the yield limit. The strain-based approach is used to calculate the factor of safety. Moreover, a comprehensive case study is presented, illustrating how design modifications can enhance the thermal fatigue factor of safety. By adjusting parameters such as thickness and routing, engineers can mitigate thermal stresses and improve the tube’s fatigue life. This approach allows analysts to thoroughly evaluate whether the tube design can endure thermal fatigue for a specified number of cycles. By utilizing advanced simulation tools and techniques, engineers gain valuable insights into the tube’s behavior under varying thermal conditions. This enables informed decision-making regarding design modifications aimed at enhancing durability and reliability. Ultimately, the integration of CAE in the optimization process empowers automotive manufacturers to develop EGR tubes that meet stringent performance requirements while minimizing the risk of premature failure due to thermal stresses and fatigue. The tool used for simulation of the EGR tube assembly is ANSYS 2023R1.