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In this paper, we will discuss whether modal analysis in hot condition is required to be analyzed or not. Exhaust system design has become a tough and challenging job to validate the structural integrity of a commercial vehicle. There is a need to reduce time in development cycle for a new product which has been a major challenge faced by auto makers to stay competitive in rapid growing automotive industry. Impacts of temperature effects on casted & tubular exhaust manifold are compared, which will be useful for valuable product design. For this, temperature distribution are mapped from CFD software and then analyzed in FEA software with structural boundary conditions in both hot and cold conditions. The exhaust manifold is close to the engine part in automotive exhaust system, because the cylinder discharge gas temperature can reach 800°C above, the tail gas heating effect is obvious.

Shoebox catalytic converter design to securely mount thinwall substrates with uniform mounting mat Gap Bulk Density (GBD) around the substrate is developed and validated. Computational Fluid Dynamic (CFD) analysis, using heat transfer predictions with and without chemical reaction, allows to carefully select the mounting mat material for the targeted shell skin temperature. CFD analysis enables to design the converter inlet and outlet cones to obtain uniform exhaust gas flow to achieve maximum converter performance and reduce mat erosion. Finite Element Analysis (FEA) is used to design and optimize manufacturing tool geometry and control process. FEA gives insight to simulate the canning process using displacement control to identify and optimize the closing speed and load to achieve uniform mat Gap Bulk Density between the shell and the substrate.

Computational Analysis and Engineering using P-Cat, WAVE, HeatCad, Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) are sequentially applied to design, develop, and optimize catalytic converter. P-Cat is used to estimate back pressure due to substrates, end cones, and inlet/outlet pipes. WAVE simulation is used to predict the exhaust system back pressure from the engine headface to tail pipe to estimate engine performance. Heatcad, a transient heat transfer analysis is used to simulate the temperature response in the exhaust system to locate the catalytic converter to achieve maximum performance. Heatcad analysis provides the easy way to identify thermal management issues and to design and optimize the runner lengths, material thicknesses of the manifold and downpipes.