Investigation and Design Modification in Exhaust Manifold

This paper aims in re-designing an exhaust manifold by determining the 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 viewpoint of reliability and serviceability. Defects in the existing manifold are cracks usually occur due to prolonged exposure to extreme temperatures, defects in casting and repeated heat cycling. Welded regions and the curved profiles are the critical regions of failure. A methodology is developed to ensure the best-suited design and material for the given operating conditions. Manifold behavior in Cast Iron is analyzed. Redesigning the curved profiles can reduce the turbulence effect of the exhaust gases on the welds. The software used Creo 3.0 for preparing the CAD model of a 4-1 exhaust manifold.