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Increasingly stringent exhaust emission regulations, which are expected to come into force within the next couple of years will require substantial reductions of NOx as well as particulate emissions. To meet these future emission standards, the application of new technologies will be indispensable, especially in view of maintaining or even improving the thermal efficiency of LD, MD and HD diesel engines [1]. Exhaust Gas Recirculation (EGR) is a proven method to reduce NOx emissions. This paper outlines the development and layout of a high load EGR system by means of 3D-CFD and thermodynamic cycle simulation. The analytical approach is presented and simulation results are compared to those achieved on the test bed.

One powerful tool for the optimization of engineering components is solution 200 of MSC/Nastran. The user is able to define nearly every kind of objective function and restriction with the help of synthetic responses, in addition to the usual responses. For sizing problems, solution 200 is well-established and reasonably user-friendly. This is not the case in the field of shape optimization. The main problem is the creation of basis vectors, which are needed to describe the shape variations. There are some methods included in solution 200 to create these vectors, but for complex engineering components these methods are difficult to use and very time-consuming. The program Shape200 has been developed to reduce the effort required to create basis vectors.