Recently, Exhaust Gas Recirculation (EGR) system which re-flew a cooled exhaust gas from vehicles burning diesel as fuel to a combustion chamber of engine has been used to solve the serious air pollution. For the design and mass production of EGR system, it is essential to ensure structural integrity evaluation. The EGR system consisted of ten dimpled oval core rectangular tubes, two fix-plates, two coolant pipes, shell body and two flanges in this study. To confirm the safety of the designed system, finite element modeling about each component such as the dimpled oval core tube with the dimpled shape and others was carried out. The reliability of EGR system against exhaust gas flow with high temperature was investigated by flow and pressure analysis in the system. Also, thermal and strength analysis were verified the safety of EGR system against temperature change in the shell and tubes. Furthermore, modal analysis using ANSYS was also performed. From the results of FE analysis, there were confirmed that EGR system was safe against the flow of exhaust gas, temperature change in EGR system and vibration on operation condition, respectively.
