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Thermal Analysis of Exhaust Manifold Coating with High Temperature Resistant Materials

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Thermal Analysis of Exhaust Manifold Coating with High Temperature Resistant Materials CORE Metadata, citation and similar papers at core.ac.uk Provided by International Journal of Science Engineering and Advance Technology (IJSEAT) ISSN 2321-6905 DECEMBER-2015 International Journal of Science Engineering and Advance Technology, IJSEAT, Vol. 3, Issue 12 Thermal Analysis of Exhaust Manifold Coating with High Temperature Resistant Materials 1K.V.V Durga Prasad 2 Sanmala Rajasekhar 3 K. Mohan Krishna 4J.Hari Narayana Rao 1 M. Tech. Student, 2Associate.Professor, 3Assistant.Professor Dept Of ME, KITS , DIVILI 4Reserch Scholar Abstract: In IC engines exhaust system plays an Lenoir around 1859 and the first modern internal important role in delivering the waste gases to a safe combustion engine was created in 1864 by Siegfried distance and also it helps in reducing the sound Marcus. pollution and air pollution ,these exhaust systems The term internal combustion engine usually ,mainly exhaust manifolds suffer a lot of thermal refers to an engine in which combustion is stress the life of the manifold is much effected due to intermittent, such as the more familiar stroke the exposer with hot flue gases ,sometimes due to and two-stroke piston engines, along with variants, emissive heating these manifolds will get blow holes such as the six-stroke piston engine and the Wankel and produce a lot of noise , zirconia based materials rotary engine. A second class of internal combustion exhibits low thermal conductivity, high hardness, and engines use continuous combustion: gas turbines, jet stable fracture toughness compared to other evaluated engines and most rocket engines, each of which are materials. One material that can be applicable in internal combustion engines on the same principle as diesel exhaust application is mullite, which showed previously described. Firearms are also a form of similar performance to zirconia based materials. internal combustion engine. In this study we design a exhaust manifold Internal combustion engines are quite with different coatings on it and we test it with Finite different from external combustion engines, such Element Methodology, but due to design limitations as steam or Sterling engines, in which the energy is and some messing problem the work is carried delivered to a working fluid not consisting of, mixed forward by assuming complete body with coating with, or contaminated by combustion products. material both temperature distribution and thermal Working fluids can be air, hot water, pressurized or stress concentrations are calculated using Finite even liquid sodium, heated in a boiler. ICEs are Element Methodology. For modelling Catia V5 R20 usually powered by energy-dense fuels such as is used and for Finite Element Methodology Ansys gasoline or diesel, liquids derived from fossil fuels. 15.0 is used. While there are many stationary applications, most ICEs are used in mobile applications and are the 1. INTRODUCTION dominant power supply for vehicles such as cars, An internal combustion engine (ICE) is aircraft, and boats. a heat engine where the combustion of a fuel occurs with an oxidizer (usually air) in a combustion 1.1 Exhaust Materials chamber that is an integral part of the working fluid Usually, header systems are fabricated from flow circuit. In an internal combustion engine the welded-up collections of cuts from pre-formed "U" expansion of the high-temperature and high- bends and straight segments of tubing in the chosen pressure gases produced by combustion apply material. There are several reasons for that, but the direct force to some component of the engine. The most persuasive is the fact that, in order to achieve force is applied typically to pistons, turbine blades, or the design single configuration, there is not usually a nozzle. This force moves the component over a ample grip-space between bends to form the pipes distance, transforming chemical energy into useful from a piece of tube. In some cases, where the bends mechanical. The first commercially successful are not too closely spaced, the pipes can be bent up in internal combustion engine was created by Étienne one piece using a mandrel bender which will retain the circular cross section of the tube throughout the www.ijseat.com Page 1207 ISSN 2321-6905 NOVEMBER-2015 International Journal of Science Engineering and Advance Technology, IJSEAT, Vol 3, Issue 11 bend and transition. The typical exhaust tube bender sections from sheet. The yield strength of this alloy at commonly found in automotive exhaust shops is not 650 °C (1200°F) is 345 MPa (50 ksi), while at 870°C suitable for that duty since those benders distort the (1600°F) it is a remarkable 276 MPa (40 ksi). As cross-section of the bends terribly and shrink the with many metals, the high-temperature strength cross-sectional area. diminishes as the amount of time the parts are Tubing bend radii (the radius of the plan- exposed to extreme temperatures increases. view centerline of the bend) are expressed in terms of 1.2 NASCAR Cup multiples of the tubing diameter. For example, a "1.5- The required Cup engine configuration (90° D bend" in 2-inch diameter tubing would have a bend V8 with a two-plane crankshaft) provides an radius of 3 inches. One fabricator described some interesting challenge for exhaust system designers. specialized machinery he had devised for making Because of the firing order of this engine high-quality exhaust tubing from sheet. The first configuration, the exhaust pulses on each bank of the machine rolls the sheets into straight tube sections of engine are unevenly-spaced. In the words of the the required diameter. The second machine completes technical director of one prominent team: "The the straight section of tube with a continuous welded exhaust system design in Cup is an interesting seam using a semiautomatic inert-gas-shielded tradeoff between minimizing flow losses while at the process. A third machine does what had been thought same time trying to optimize whatever tuning you to be impossible: bending 0.50-mm wall inconel can do with a non-equally-spaced system, which isn't tubes into less-than-1-D radius sections while a lot." retaining accurate cross-sectional geometry. With the GM cylinder-numbering system (1- There are several materials commonly used 3-5-7 on the left) and firing order {18436572; the 4-7 in competition header and exhaust systems, swap is not allowed in Cup} ), the exhaust pulse depending on the requirements and operating spacing on the left side (expressed in terms of temperatures. degrees of crankshaft rotation) is 270°-180°-90°-180° For the most demanding applications, while the spacing on the right side is 90°-180°-270°- Inconel tubing is commonly used. Although the name 180°. This uneven pulse spacing gravely impedes the "Inconel" is a registered trademark of Special Metals achievement of a well-tuned exhaust system such as Corp., the term has become something of a generic can be achieved with evenly-spaced pulses and a 4- reference to a family of austenitic nickel-chromium- into-1 collector. based superalloys which have good strength at That tuning difficulty led (more than a extreme temperatures and are resistant to oxidization decade ago) to the re-introduction of the 4-into-2- and corrosion. Because of the excellent high- into-1 (so-called "Tri-Y") configuration, which has temperature properties, Inconel can offer increased been around since at least the 1960's. In the "Tri-Y", reliability in header systems, and in certain cylinders on each bank are paired so as to provide the applications, it is the only material which will do. maximum separation between pulses. Using the The high-temperature strength properties can enable above numbering scheme, the primaries of cylinders weight-reducing designs, since, for a given reliability 1 & 5 and 3 & 7 would be merged into slightly larger requirement, Inconel allows the use of much thinner- secondary pipes, which after the appropriate length, wall tubing than could be used with other materials. would be merged into the larger collector. On the The catch, as usual, is that Inconel tubing is quite right side, adjacent primaries are paired (2 & 4, 6 & expensive. 8). That provides a 450°-270° separation between Certain Inconel alloys retain very high pulses in each secondary. strength at elevated temperatures. One of the 2. CATIA favorites for header applications is Inconel-625, a solid-solution alloy containing 58% Nickel, 22% CATIA also known as Computer Aided Chromium, 9% Molybdenum, 5% Iron, 3.5% Three-dimensional Interactive Application and it is Niobium, 1% Cobalt. It has good weldability using software suit that developed by the French company inert-gas-shielded-arc processes, and good call Dassult Systems. formability in the annealed condition, and has a lower CATIA is a process-centric computer-aided thermal expansion rate than the stainless alloys design/computer-assisted manufacturing/computer- commonly used in exhaust systems. Weldability and aided engineering (CAD/CAM/CAE) system that formability are both important because of the fully uses next generation object technologies and somewhat limited availability of Inconel tubing sizes, leading edge industry standards. CATIA is integrated which often makes it necessary to form tubing with Dassult Systems Product Lifecycle Management www.ijseat.com Page 1208 ISSN 2321-6905 NOVEMBER-2015 International Journal of Science Engineering and Advance Technology, IJSEAT, Vol 3, Issue 11 (PLM) solutions. It allows the users to simulate their industrial design processes from initial concept to product design, analysis, assembly and also maintenance. In this software, it includes mechanical, and shape design, styling, product synthesis, equipment and systems engineering, NC manufacturing, analysis and simulation, and industrial plant design. It is very user friendly software because CATIA Knowledge ware allows broad communities of user to easily capture and share know-how, rules, and other intellectual property assets.
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