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Modern cylinder-head designs for gasoline engines are guiding the exhaust gas to the turbocharger system via an integrated exhaust manifold (IEM) which has several advantages like weight and cost reduction. On the other hand, the exhaust ports are running through a package labyrinth and are heavily bent within smallest space. Increased pressure drop, reduced mass flow rate, and deteriorated port flow efficiency could be the consequences leading to higher emissions, increased fuel consumption, and higher knock sensitivity. The optimization of the individual ports by computational fluid dynamics (CFD) is a proper means to minimize or even delete these drawbacks. Meanwhile, there are several powerful optimization methods for three-dimensional flows on the market. In this paper, a combined optimization strategy using CFD topology optimization followed by a shape optimization is presented.

A new CFD simulation model and methodology for oil jet piston cooling has been developed using the modern level set approach. In contrast to the widely used volume of fluid (VOF) method, the level set approach explicitly tracks the interface surface between oil and air, using an additional field equation. The method has been extensively tested on two- and three-dimensional examples using results from literature for comparison. Furthermore, several applications of oil jet piston cooling on Ford engines have been investigated and demonstrated. For example, three-dimensional simulations of piston cooling nozzle jets on a diesel engine have been calculated and compared to test-rig measurements. Laminar jets, as well as jets with droplets and fully atomized jets, have been simulated using realistic material properties, surface tension, and gravity.