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Structural Analysis of Passenger Car Exhaust System by Using Hypermesh

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Structural Analysis of Passenger Car Exhaust System by Using Hypermesh International Journal of Emerging Technologies in Engineering Research (IJETER) Volume 3, Issue 2, November (2015) www.ijeter.everscience.org Structural Analysis of Passenger Car Exhaust System by Using Hypermesh Venugopala Reddy Kussam Research Scholar, Nova College of Engineering and Technology, Jangareddy Gudem, West Godavari (Dt), India. Jithendra Kumar B Associate Professor, Nova College of Engineering and Technology, Jangareddy Gudem, West Godavari (Dt), India. Abstract – The Automobile exhaust system is used for silencing Dr. S. Rajadurai et al., [02] this paper deals, to evaluate the the noise caused by the high pressure exhaust gases are releasing durability of exhaust system components by CAE Simulation. in to the atmosphere. It is important to control the emissions and Finite element simulation are carried out and the results are a part of combustion. Exhaust systems are a special type of size explained for the typical exhaust system components and geometry, the constraints placed in the design of a car. It is considering the durability loads such as engine vibration found that the induced vibrations are spread along the exhaust system and the forces are transmitted to the car body. To reduce loading, proving ground road loads. The durability issues the forces, adding of decoupling elements like flex-couplings and associated with the exhaust system components such as isolators are used. The vibrations could induce structural noise in muffler-pipe system, brackets and hanger designs are analyzed. the passenger car. The adopting procedure includes a correlation Johan Wall Karlskrona, [03] describes the Low vibration levels and model updating step can be done by using Finite element method and optimization technique. are a critical objective in automobile exhaust system design. It is therefore important for design engineers to be able to predict, Index Terms – Automobile, Exhaust, Hypermesh. describe and assess the dynamics of various system design 1. INTRODUCTION proposals during product development. Every increasing demand for durability, lighter and cost Sanjay S. Patiletal., [04] deal with dynamic analysis of a effective designs of automotive products have led to more modular automotive exhaust system where it is directly frequent usage of powerful Numerical techniques for solving mounted on power train pack. Selection of dynamic loads, structural problems. In the automotive industry, the detection processing of the test data, and effect of assembly loads along of structural failures has traditionally relied on proving ground with material property variation due to temperature are road load tests. It is generally recognized that developing explained. designs through testing and retesting using several prototypes 3. OVERVIEW OF EXHAUST SYSTEM is not helping in accelerating the product development. Hence virtual structural calculations of automotive components have become an essential part for vehicle manufacturers. The laboratory test offers durability evaluation for the exhaust system, which could provide information. Comparing to laboratory tests, CAE is another tool, which could be employed for improving durability performance of exhaust components while reducing significant product development costs and time. CAE not only evaluate durability performance, but also explores many possible design options and promises to yield optimum design with significant experimental cost and time savings. Figure 1Typical exhaust system design. 2. LITERATURE REVIEW Exhaust system plays an important role in the performance of the vehicle. It carries out all the burnt gasses from engine to H. Bartlett et al., [01] this paper presents the modelling and atmosphere. As a traditional procedure, track tests are made to analysis of variable geometry, exhaust gas systems. An assure the proper structural design of vehicles and life automotive example is considered whereby the pulsating determination. There is a worldwide trend to use more exhausts gas flow through an exhaust pipe and silencer are computer simulation structural behavior and decreases the time considered over a wide range of speeds. to market and coasts. A complicated real world environment seen by an exhaust system in the vehicle can be simplified and ISSN: 2454-6410 ©EverScience Publications 31 International Journal of Emerging Technologies in Engineering Research (IJETER) Volume 3, Issue 2, November (2015) www.ijeter.everscience.org modelled using numerical simulation. By using engineering 4.1. Objectives of the Project experience and time-tested assumptions, valuable information The main Objectives of the Projects are: can be acquired in relatively cost and time-effective way, thanks to the computation power boosted in recent years. To generate a finite element model of the Exhaust system 3.1. Components of passenger car exhaust system are 1. Catalytic Converter. To carry out the all necessary checks on the model 2. Exhaust Manifold To determine the Natural frequency of the Exhaust system[Normal mode analysis] 3. Exhaust - pipe system Muffler Bracket design. Stress analysis on the whole exhaust system model 4. Exhaust Clamps, Hangers and Brackets under 1G and road load condition. 5. Mufflers 6. Exhaust Flange To determine the Max displacement and Reaction 7. Vibration isolator forces on the Bracket and hanger location under 1G and 5G static loading.[Static analysis] 8. Flexible Coupling To determine the Max Displacement, under dynamic 9. Tail pipe loading [Modal Frequency response] at different location in the exhaust system. The natural frequencies obtained from the normal mode analysis are compared with the experimental results. 4.2. Scope of the Project Modal analysis (SOL103) is carried out for complete exhaust system to determine the first natural frequency of exhaust system and also to check the resonance frequency. Static analysis (SOL101) is carried out to check the Figure 2 Schematic Diagram Of passenger Car Exhaust distribution of displacement and reaction forces at the System rubber mount location of the exhaust system. Automobile exhaust system refers to a group of independent Dynamic analysis is performed to check the but interrelated automotive components used to direct the displacement at different location of the exhaust waste exhaust gases out of the combustion chamber of an system. engine. Based on its design the exhaust system comprises Comparison study for normal modal analysis for several different parts such as a cylinder head and exhaust exhaust system assembly by experimental and manifold, a turbocharger to enhance engine power, catalytic numerical approach. converters for air pollution reduction, a muffler or a silencer to 4.3. Methodology reduce noise and one or more exhaust pipes. In this project, Finite Element analyses were used to determine 4. STATEMENT OF THE PROBLEM the characteristics of the Exhaust system. All methodology The automotive industry is heading in the direction of signing principles and theories discussed were utilized to achieve the off the exhaust system durability based on computer simulation project’s objectives. The combination of all the analysis results rather than rig simulation and physical vehicle testing. This is were used to develop virtual model created using FEM tools due to the cost, time and availability of prototype vehicles and and the model was updated based on the correlation process. test track. Use of Finite Element Method (FEM) enables to The research methodology flowchart for this project was assure the structural integrity of the exhaust system and also shown in Figure 3. contribute to better understanding of the system behavior in the various operating conditions and evaluation of structural strength. ISSN: 2454-6410 ©EverScience Publications 32 International Journal of Emerging Technologies in Engineering Research (IJETER) Volume 3, Issue 2, November (2015) www.ijeter.everscience.org 5.3. 3D catiaV-5 Model Figure 5 Representation of exhaust system in 3D view 5.4. Material Property Stainless steel started to be used as material for decoration in automobile. However, in recent years, it is mostly used as material for the exhaust system. It is because those stainless steels with good performance of high temperature characteristics and high corrosion resistance meet the social needs for clean exhaust gases and reduced weight for better fuel economy. Material used for structural analysis of Exhaust system is Stainless Steel (SUS 304B).The isotropic material properties used in a FEA analysis are as follows: Mechanical property of S.No Stainless Steel 1 Young’s Modulus(E) 2.08x105 N/mm2 2 Poisson’s Ratio() 0.31 3 Density() 7.85x10-9Ton/mm3 Figure 3 Flow chart of different stages in the project 2 4 Yield Stress(y) 350 N/mm 5. GEOMETRICAL CONFIGURATION AND MATERIAL PROPERITY OF THE EXHAUST 5 Ultimate Strength( ) 450 N/mm2 SYSTEM u 5.1. CAD Model Table1 Mechanical properties of steel material used in The CAD model of Hyundai i10 passenger car exhaust system Exhaust system for analysis is provided by Sharda Motor Industries Limited, 5.5. Geometrical Overview Chennai. The present exhaust system is taken over for analysis. 5.2. 2D Drafted CAD Model Figure 4 Schematic front and bottom view of 2D drafted model Figure 6 Complete Representation of Exhaust System ISSN: 2454-6410 ©EverScience Publications 33 International Journal of Emerging Technologies in Engineering Research (IJETER) Volume 3, Issue 2, November (2015) www.ijeter.everscience.org 6. FINITE ELEMENT METHOD S.NO Type of element No of
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