INTERNATIONAL RESEARCH JOURNAL OF MULTIDISCIPLINARY TECHNOVATION (IRJMT)

http://www.mapletreejournals.com/index.php/irjmt
Received 16 August 2020 ISSN 2582-1040
Accepted 31 October 2020 2020; 2(6);1-8
Published online 13 November 2020

Design and Analysis of Exhaust Manifold

Anand D 1, Suresh Vellingiri 1, *
1
Department of Mechanical Engineering, Holy Mary Institute of Technology and Science, Hyderabad,
Telangana-501301, India.
*Corresponding author E-Mail ID: winsureshv2011@gmail.com

DOI: https://doi.org/10.34256/irjmt2061
Abstract
The exhaust manifold system is mountedon the cylinder head of theengine. It is associated
with the catalyst converter at the other end. The emitted gases transmitted from the chamber come
out at temperatures of about 800 °C and with pressures extending from 100 to 500 kPa. The
exhaust manifold system is exposed to high temperatures and weights which will lead to thermo
mechanical failure. Redesigning an exhaust manifold by determining Thermal stresses and
deflections exhibited under various operating conditions with different materials and
temperatures. The objective is to ensure the suitability of the design for a particular material from
the view point of reliability and serviceability. Defects in existing manifold are cracks usually
occur due to prolonged exposure to extreme temperatures, defects in casting and Heat cycling.
High end cad cam software such as Unigraphics and Ansys is used for modeling and analysis. The
3d Model of exhaust manifold is subjected to thermal and structural loads and results are tabulated
according to the procedure for the Exhaust manifold.
Keywords: Thermal Stresses, Unigraphics, Ansys, Manifold, Materials.

1. Introduction
Exhaust manifold gets the exhaust gases comes out from chamber and goes to
condition. The generally collected with chamber. Cast iron is material utilized for ventilation
systems. Components to be considered during the plan and improvement of ventilation system [1].
The exhaust manifold is a piece of a diesel motor that can be required to gather fumes gases from
the chamber head and send it to the gases gadget. Gases wholesaler assumes a key job in the
general effectiveness of an engine device. Particularly, the emanation productivity and gas
utilization are nearly connected to the ventilation system. The gatherer can throw or produced
using a somewhat light cloth. The reason for the exhaust manifold is the procurement and
conveyance of these fumes gases from the chamber with no less pressure. Exhaust manifold are
exhausted because of warm strain and disfigurement because of temperature dispersion, heat
collections or scattering, and different related warm extent [2-4].
The point of our analysis is to discover exactness fabric by evaluating thermal
strain and deformation prompted by mapping the temperature on one of the sorts of substance for
the rough terrain diesel motor ventilation system. In this endeavor, we are examining the rough
terrain diesel motor ventilation system. In the underlying advance, FEM analysis were made on
the issue by utilizing first-request tetrahedrone detail and the blending test was cultivated by
assistant weight, affirmation of the top decision. Warm assessment in the subsequent advance to
decide the temperature map, heat slipping, and normal heat switch characteristics.
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The outcomes are successively utilized as a contribution to the computation of stress,

stress and miss happening, and affirm whether the segment geometry addresses a specific issue for
conductivity. Info estimations of the temperature are assembled through test testing of the
assessment remarks. The trial estimations of the temperature flow were attempted with the
delayed consequences of the FEA steady warm examination. The ventilation framework is a bit of
an inside engine that assembles fumes gases from more than one chamber into one channel.
Numerous ventilation frameworks are made of cast iron or nodular iron. Some are made of
hardened steel or overwhelming steel[5-8].
VVRLS Gangadhar et al., 2017, done an assessment, in which a current model of an
engine Exhaust Manifold is shown in 3D displaying programming. Warm investigation is
accomplished for the two models utilizing various materials copper, Nickel, Stainless steel and
manganese. Investigation is done in ANSYS. By watching the warm investigation results, the
warmth motion (i.e) heat move rate is more for Copper when contrasted and different materials.
The warmth move rate is marginally less for altered model than unique model [9].
KanupriyaBajpai et al., 2017, in their work, the presentation of a four-stroke four cylinder
gasoline engine exhaust manifold have been investigated utilizing three distinct powers - fuel,
liquor, and LPG for the estimation of stream traits, warm characteristics, and least back weight.
The complex demonstrating is done in Creo2.0 followed by lattice and examination in
ANSYS[10].
P Sylvester Selvanathan et al., 2017, examined the arrangement of a ventilation framework
to develop the significance of various factors related with arranging a exhaust manifold by
looking at different existing plans utilizing Computational Fluid Dynamics[11].
Puneetha C G et al., 2015 thoroughly explores four unique models of exhaust silencer and
wraps up the best arrangement for least weight drop. Back weight was gotten subject to the stream
field examination and was furthermore differentiated and all silencer plan. Virtual reenactment for
back-pressure testing is performed by Computational Fluid Dynamic (CFD) examination using
Acusolve CFD. Restricted Element (FE) model age of the silencer structure is performed using
Hyper Mesh as the preprocessor. The auxiliary work is displayed utilizing 2D shell components,
wherein the interior cylinders with fine punctured openings are considered[12].
MarupillaAkhilTeja et al., 2016, In general engine execution of an engine can be gained
from the right arrangement of engine vapor structures of motor fumes frameworks. As to severe
emanation enactment in the car area, there is a need plan and create reasonable burning chambers,
bay, and outlet complex. Ventilation system framework is one of the critical parts which impact
the engine execution. Course through a ventilation framework is time subordinate concerning
wrench point position. In the ebb and flow research work, numerical examination on four-
chamber oil engine with two ventilation framework running at reliable speed of 2800 rpm was
inspected [13].
V. Ashok Kumar et al., 2016 focused on CFD and warm assessment with different weights
(2, 6,12,14,16 and 18 kg). Warm examination accomplished for the ventilation system by cast
iron, tempered steel, silicon nitride& zinc oxide. In this proposition the CFD investigation to
decide the warmth move rate, mass stream rate, constrain drop and warm examination to decide
the temperature circulation, heat motion with various materials. 3D displayed in parametric
programming Pro-Engineer and investigation done in ANSYS [14].
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2. Methodology and Modeling

This article aims in redesigning an exhaust manifold by deciding Thermal burdens and
diversions showed under different working conditions with various materials and temperatures.
Perform coupled flied investigation on the ventilation system for compel burden and warm burden
to discover pressure and redirection. Perform warm investigation on the complex framework for
heap of warm. Common frequencies mode shape and there mass co operations are plotted. Most
extreme diversion and stress are determined at top reaction.
2.1 Computer Aided Design (CAD)
Computer-aided design0(CAD), also known as computer-aided design and drafting
(CADD), is the utilization of computer0systems to aid the creation, change, examination, or
improvement of a structure. PC helped drafting depicts the way toward making a specialized
drawing with the utilization of program. Computer aided design programming is utilized to
expand the efficiency of the creator, improve correspondences nature of configuration, improve
communications0through documentation, and to make a database for assembling. Computer aided
design yield is frequently as electronic documents for print or machining tasks. Computer aided
design programming utilizes either vector based illustrations to portray the objects of conventional
drafting, or may likewise create raster illustrations demonstrating the generally speaking
appearance of designed objects.

Figure 1. Methodology
As in the manual drafting of specific and building drawings, the yield of CAD must pass
on information, for instance, materials, techniques, estimations, and versatilities, as demonstrated
by application-express shows. PC supported plan may be used to setup twists and figures in two-
dimensional(2D) space;or curves, surfaces, and solids in three-dimensional(3D) space.
PC supported structure is a critical mechanical workmanship extensively used in various
applications, including vehicle, shipbuilding, and avionics undertakings, present day and auxiliary
arrangement, prosthetics, and some more. PC helped configuration is moreover commonly used to
convey PC vivacity for frivolity sin movies, publicizing and concentrated manuals. The front line
all inclusiveness and force of PCs suggests that even smell containers and chemical holders are
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organized using techniques tremendous by planners of the 1960s. Because of its tremendous
money related criticalness, CAD has been a huge principle stimulus for investigate in
computational geometry, PC graphics(both gear and programming), and discrete
differentialgeometry. PC helped configuration showing shows of ventilation framework as in
Figure 2.

Figure 2. Front view of exhaust manifold

3. Finite Element Analysis of Exhaust Manifold

The Basic thought in FEA is that the body or structure may be divided into smaller parts of
constrained estimations called "Restricted Elements". The primary body or the structure is then
considered as a social affair of these parts related at a predetermined number of joints called
"Hubs" or "Nodal Points". Direct limits are picked to deduce the evacuations over each
restricted segment. Such acknowledged limits are assigned "shape limits". This will address the
migration with in the part in regards to the expulsion at the centers of the segment.
The Finite Element Method is a numerical instrument for comprehending standard and
fractional differential conditions. Since it is a numerical apparatus, it can take care of the intricate
issues that can be spoken to in differential conditions structure. The uses of FEM are boundless as
respects the arrangement of pragmatic structure issues. Due to high cost of computing power of
years gone by, FEA has a history of being utilized to tackle complex and cost basic issues. Old
style techniques alone generally can't give sufficient data to decide the protected working
constraints of a significant structural building development or a car or an airplane. In the ongoing
years, FEA has been all around used to take care of basic designing issues.
The divisions, which are intensely depended on this innovation, are the car and aeronautic
trade. Because of the need to satisfy the extraordinary needs for quicker, more grounded,
proficient and lightweight cars and airplane, makers need to depend on this procedure to remain
serious.
FEA has been utilized routinely in high volume creation and assembling enterprises for a
long time, as to get an item configuration wrong would be impeding.
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For instance, if an enormous maker needed to review one model alone because of a hand
brake configuration issue, they would wind up supplanting up to not many millions of hand
brakes. This will cause a heavier loss to the company.
Structural analysis contains the arrangement of physical laws and science required to
consider and predicts the conduct of structures. The subjects of helper examination are planning
doodads whose uprightness is decided by and large reliant on their ability to withstand loads; they
generally incorporate structures, scaffolds, airplane, and boats. Basic investigation merges the
fields of mechanics and components similarly as the various disappointment hypotheses. From a
hypothetical point of view the essential objective of auxiliary investigation is the calculation of
deformations, internal forces, and stresses. In structural analysis of modified exhaust manifold, we
have to apply structural and thermal loads. The bolts are arrested in all Dof, and pressure load
500000Pa is applied inside of the exhaust pipes temperature distribution is applied as Thermal
loads on modified exhaust manifold from the thermal analysis.

Figure 3. Mesh model of Exhaust manifold

Figure 4. Nodal displacementson exhaust manifold.

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Figure 5. Temperature distribution on exhaust manifold.

Figure 6. Von Mises stress of exhaust manifold.

The bolting locations are arrested in all Dof for modified exhaust manifold. Thermal
analysis is done to find the temperature conveyance on the altered ventilation system. These
temperatures are applied as the body stacks in the structure analysis. The Max Deflection
0.054mm observed on the exhaust manifold for operating loading conditions. The Max Avg.
VonMises Stress observed 39.05Mpa on the segway assembly for operating loading conditions.
And the Yield strength of the materials cast iron is 600Mpa.
4. Conclusions
In this paper examined couple field examination of exhaust manifold system at most
extreme temperature and weight condition by utilizing aluminum and castiron materials. Thermal
vonmisesstress observed 141.29Mpa on the segway gathering for working stacking conditions.
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What's more, the Yield quality of the materials Aluminum is 180Mpa. Here 21.5 % stress less
framed for Aluminum that of yield quality. Thermal vonmises stress observed 39.05Mpa on the
segway get together for working stacking conditions. Also, the Yield quality of the materials cast
iron is 600Mpa. Here 93.49 % stress less shaped for Cast iron that of yield quality. Compare both
results, cast iron formed less thermal stresses during loading conditions on manifold.
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Acknowledgement Nil

Funding
This study was not funded by any grant

Conflict of interest
None of the authors have any conflicts of interest to declare.

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The text of this article is licensed under a Creative Commons Attribution 4.0 International License

Cite this Article

Anand D, Suresh Vellingiri, Design and Analysis of Exhaust Manifold, International Research
Journal of Multidisciplinary Technovation, Vol 2, Iss 6 (2020) 1-8.
DOI: https://doi.org/10.34256/irjmt2026