Static Analysis of Weldless Exhaust System Fitting by FEA

This study focuses on the development of a reliable approach to predict failure of exhaust system fitting and on the removal of structural weaknesses through the optimization of design. The task with this project was to find a new solution concept for the connection of pipes into flanges in manifolds. The concept that a uses today for their manifolds is based on welding the pipes into place in the flange. The product development model that is used in this project is written by Fredy Olsson. For this project have the parts “Principal construction” and” Primary construction” been used. The Objective is to present experimentation, modeling and analysis of exhaust system fitting weldless by using FEA. Modeling is done using CATIA .Analysis is carried out by using ANSYS. The optimization of cast and fabricated manifolds (single or dual wall design) requires different techniques, due to the production restrictions. The locations where failures occur, on both the exhaust manifolds (cast or fabricated) and exhaust manifold gaskets, are predicted with high degree of accuracy. From the study it is seen that the different solution concept is result from this work. All of the solution concepts contain end shaped pipes that provides the sealing area against the engine. The main difference between them is that the flange is designed in different ways. Different techniques are needed for the optimization of cast and fabricated manifolds, because of production restrictions. This problem is already been addressed and a procedure has been implemented. The manual and automatic optimization methods have distinct advantages and disadvantages. A cost effective solution is delivered by a combined methodology, which also results in a failure-free exhaust manifold design.