Structural Durability Evaluation of Exhaust System Components 2007-01-0467

In this paper, a combined analytical CAE procedure and durability experiments are used to calculate the durability of complete exhaust system. Detailed analytical calculations are carried out and the results are explained for the typical exhaust system components considering the durability loads such as engine vibration loading, proving ground road loads, thermal loads, loads created due to geometric dimensioning and tolerances (GD & T), and bolt loads. The durability issues associated with the exhaust system components such as hot-end brackets, converter cone-pipe region, exhaust pipe system, muffler-pipe system, muffler hanger designs, and residual stresses in an exhaust system assembly such as ball joint flange-flange interface, and hot-end converters are explained in detail. Both experimental results and analytical calculations are carried out. Detailed analysis of the existing designs of exhaust components and the description of the evolution process of the improved designs are explained.