Design and Analysis of An Integrated Exhaust Manifold with Turbocharger for Considerable Reduction of Over Heating of Bearing System

Presently in turbocharger, turbine housing and exhaust manifold are supplied as two separate components to the engine manufacturer. It was observed that the flow path in the exhaust manifold was improper and led to high temperature region in the turbine housing and bearing housing. Due to the high temperature region, burning issues were observed in practical conditions. To avoid high temperature region and turbocharger failure, a proposal was made to combine the exhaust manifold and turbine housing. 3D CAD models of the existing design and the proposed integrated design were modeled using Creo Parametric 2.0 software package. Computational Fluid Dynamics (CFD) simulations were conducted on existing design to determine the heat distribution in the manifold and turbine housing. Heat transfer CFD simulations were conducted on the integrated turbine housing to determine the modified heat distribution over the turbine housing and bearing housing. The exhaust flow path in the integrated manifold was optimized to reduce the stagnation region and pressure losses of exhaust gas flow. To verify the strength of the turbine housing at high temperatures, Thermal Mechanical Fatigue (TMF) simulations were conducted on the optimized design. Using the integrated turbine housing design, the weight and manufacturing cost can be reduced and also the turbocharger performance and durability can be improved.