Abstract
Keywords: charge air system, reduction of pressure loss, CFD, topology optimization
In the development process of passenger cars, the optimization of charge air systems with regard to low pressure losses is a matter of growing interest. Reducing the flow resistance on the charge-air side can contribute to an enhanced engine torque and increase the engine power.
Traditionally, these systems are dimensioned on a test bench. In this paper an additional approach is presented, that aims on supporting the development process by numerical simulation methods. In the presented example, the potential of optimization for each single component in the system is revealed by calculation. The fluid flow simulation is performed with the commercial CFD code STAR-CD (1). Then some of the components are subjected to an optimization process using numerical simulation methods. Emphasis is put on the fact that the optimization can be done with minimal time and effort, otherwise it will not be applicable in an industrial development process. For that purpose, the ability and efficiency of the optimization tool AUTODUCT (2) is investigated. It implements a topology optimization method and has been developed in the research department of Daimler (3).