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A previous SAE paper (2018-01-1396), (see ref 5) introduced the concept of using the frequency domain for exhaust system analysis under road excitation as a fast and efficient approach. During the intervening period further benchmarks have confirmed the validity of the approach for several exhaust systems comparing the results of simulations performed in the time domain and frequency domain for different applications. This paper will present that data and also introduce a new technique which has been developed to create, from the originating road load data (RLD), the cutting plane loads at any desired section of the exhaust system. Those loads can be used directly to determine safety factors against load capacities based, for example, on part SN curves from current or former hardware testing or even derived from statistics.

Today in the automotive industry, there is a continual reduction in available development time. There is also an urgent need to reduce cost and weight, to adapt to customer and legislation which drives to an increase in design complexity. These challenges are sometimes made harder by the late availability of hardware and this creates the need to extend and continually improve the established CAE methods which are used to develop automotive parts. This holds especially true in the field of exhaust systems and their components, which experience loads from various sources like temperature, engine or road. In the field of road excitation the use of dynamic transient simulation and subsequent damage calculation is state of the art in terms of simulations methodology.