Bachelor Graduation Assignment: Optimization of a diesel engine EGR cooler mounting design

Optimizing EGR Cooler Performance with Advanced Simulation and DFSS Tools The CAE-engines department is responsible for creation and validation of models that can describe and predict the behaviour of the new and current engines. Due to more increasing requirements on emissions modern diesel engines have become complex systems. These emission legislations cause the need to add additional sub-systems to the base engine. All of these systems and sub-systems with pipes, lines and wiring need to be mounted to the base engine. Some of these currently use brackets or studs. To ensure the lifetime performance of the engine all these systems and subsystems need to be checked on their endurance life.

In a truck diesel engine, an Exhaust Gas Recirculation (EGR) cooler is used to reduce harmful emissions and improve engine efficiency. The EGR system recirculates a portion of the exhaust gases back into the engine's intake air. Because these exhaust gases are hot, the EGR cooler lowers their temperature before they enter the engine. Cooler exhaust gases help reduce the formation of nitrogen oxides (NOx), which are harmful pollutants. By using an EGR cooler, the engine can meet emission standards while maintaining performance and fuel efficiency.

For the system of the EGR cooler now interest has been raised to investigate if this system can be optimized while remaining similar lifetime performance. The system performance in this case should remain equal while having a weight advantage over the current system. The final design should be validated with Finite Element Method (FEM) simulations for all known loadcases.

This design study will use a lot of Design For Six Sigma (DFSS) tools to come to a well chosen final design.

• Analytical calculations as introduction to FEM.
• Numerical modelling introduction.
• Benchmarking design solutions
• Design study using DFSS tool.
• Final design choice and creation
• Final design validation
• Final design evaluation

The assignment will be mainly theoretical using Abaqus CAE as FEM software.

• A view behind the scenes at a large international corporation;You will get a lot of freedom and responsibility;
• We are open to your initiatives and depending on the assignment you see your results back in the workplace;
• An experienced coach and supervisor who can teach you a lot and is willing to help you with your assignment;
• After your graduation, you will have the opportunity to start your career at DAF;
• An internship wage of € 375,- (Bachelor) and € 450,- (Master) per month on full-time base;
• A travel allowance, if you don't have a student travel product (provided by the Dutch government);
• A housing allowance, if you temporarily rent a room near DAF.

Each intern will have the opportunity to participate at the Student Event. During this event you will meet other interns and find out more about DAF/PACCAR

Would you like to know more about the experiences of other students? Here you can read stories of our former interns. Within the PACCAR Inc. DAF Engine Development is the centre of competence for engine development. In our state-of-the-art engine development centre we develop engine families for the future regulations. Our engines and trucks are best in class products in the transportation world being always driven by providing environmentally friendly products with best cost-effectiveness and highest reliability for our customers.

The department Engine Hardware & Design is responsible for the development of new engine hardware concepts and maintaining the in-production engine families. The department is divided in 4 groups: CAE, Injection & Turbo, Base Engine and Engine Auxiliaries.

For the CAE group we have an open position for a bachelor graduate student.

• Mechanical Engineering/ Automotive Engineering
• All communication and reporting will be done in English
• Only HBO Bachelor thesis graduation students will be considered

Please upload your resume and motivation below. For more information you can contact Campus Recruitment on the phone number