Search Results

The exhaust manifold is one of the engine components which is used to collect the burned gases from the cylinder head and send it to the exhaust hot end aftertreatment system with low engine backpressure. The main purpose of the automotive exhaust manifolds are providing a smooth flow field and must be able to endure thermo-mechanical loadings. The present paper explains the CAE analysis method to assess the design of exhaust manifold of a heavy duty diesel engine. Coupled computational fluid dynamics (CFD) analyses were performed to solve the flow field within the exhaust system and surface convection loading prediction at fluid side and obtain temperature distribution at solid region of exhaust manifold domain. The metal temperature prediction provided by thermal model is used to carry out the durability analysis of the structure.

Honing is a low-speed abrading process to remove metallic and non-metallic materials from a surface. Honing corrects surface errors produced by other machining operations prior to honing. Moreover,, the honing grooves, the volume and the direction of the valleys control the amount of oil available, by keeping the oil on the bore surface and by improving the spreading of the oil. The traditional honing process that uses ceramic abrasives has been replaced by the superior abrasives that is Metal Bonded Diamond [1,2]. However, the main drawback of diamond honing is that it leaves more torn metal and folded metal on surface [3]. The folded and / or torn metal partially covers the honing grooves and interrupts oil flow in groove. Hence, it causes abrasive wear as axial scratches on the cylinder surface. Diamond is the strongest material known that is less friable, wear very little, requires more pressure and tends to plough through metal surface rather than cut.