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This paper discusses about the Flange design study carried out in Fuel Delivery Module (FDM) for meeting out contradictory requirements of robustness and crash worthiness. FDM is assembled in the fuel tank with flange covering the tank opening, and swirl pot assembly comprising fuel pump attached to flange through two steel struts. During crash, FDM undergoes sudden deceleration. Due to inertia, swirl pot assembly creates bending moment in the flange-strut interface. At such adverse condition, flange should not exhibit crack on the sealing side, as it might expose fuel in the fuel tank to the atmosphere. To ensure safety, flange-strut interface in the bottom side of flange is designed with higher stress concentration factor. So, the struts along with swirl pot assembly will break away from flange during crash without creating crack in the flange sealing faces. But failures were observed during vibration testing in the flange-strut interface with new stringent vibration requirements.

This paper discusses about the effective utilization of fluid structure interactions simulation for the pump stage development of Impeller type fuel pumps. Axial clearance between the rotating impeller and stationary components is crucial for the effective performance of the pump stage. Because of designed interference fit and operating conditions the stationary pump stage components tend to deform towards rotating impeller. Computational simulations are extensively used in the design stage to predict this deformation behaviour. As these components bear wide variety of loads like structural, thermal & hydraulic loads, it demands coupled simulation to be performed. Computational fluid dynamics simulation was performed initially to get the pressure load distribution and solved in a structural solver along with other structural and thermal loads to calculate deformation. With the Multi-physics simulation results, pump stage design was optimized for minimum deformation.