EXHAUST MANIFOLD

Design, manufacturing process and material to build an exhaust

manifold.

CLETO QUIÑONEZ MORENO

15130100

05/02/2018

UNIVERSIDAD POLITÉCNICA DE CHIHUAHUA

Contents
Introduction .................................................................................................................................................. 3
Objective of Study ........................................................................................................................................ 3
Literature ...................................................................................................................................................... 3
Assumptions ................................................................................................................................................. 4
Free Body Diagram Schematic ..................................................................................................................... 4
Hand calculations ......................................................................................................................................... 5
Mesh Specifications...................................................................................................................................... 6
Material specifications & properties ........................................................................................................... 6
Suggested manufacturing process ............................................................................................................... 6
Results........................................................................................................................................................... 7
...................................................................................................................................................................... 7
Stress strain graphic ..................................................................................................................................... 8
Conclusions ................................................................................................................................................... 9
Appendix..................................................................................................................................................... 10
Introduction

The exhaust manifold is a very important artefact for an internal combustion engine, is through of this
device that the engine throw out the gases that it produces after the internal combustion, design is
important for effects of to dissipate the heat, it is exposed to high temperatures and pressure, in this
analysis we will find the stresses that produces different pressures at the internal faces of manifold. We
will propose a material for his manufacturing and the manufacturing process.

Objective of Study

To determinate:

a) The force that causes the manifold break.

b) The necessary pressures to arrive to the plastic zone, where the body suffers permanently
plastic deformation.
c) The stress that are supported by the manifold, that keeps it in the elastic zone.
d) To represent the strain stress graphic for different pressures at different zones.
e) To find the equivalent stress and to calculate the cycles that identify the useful life of manifold.

Literature

1. MMPDS
2. MATWEB
3. Atlas of fatigue Curves
Assumptions

1. The material was considered as 17-4PH Stainless Steel Investment Casting Specification AMS 5342

2. The Load was considered as applied at the temperature of 22 degrees in Celsius scale.

3. The only load considered was the pressure normal at faces of manifold.

4. The contacts in the joins assemble was considered as bonded type.

5. Calculated displacements are directly proportional to the load applied to a part or assembly.

6. -The contact conditions between two or more parts in an assembly are treated in a linear fashion. For
stress, shape, and modal analyses, only bonded and frictionless (no separation) contact conditions are
supported.

Free Body Diagram Schematic

Hand calculations
Thick-walled cylinders

Thin-walled cylinders
 Mesh Specifications

Node Elements Method

24099 6513 Hex dominant

Material specifications & properties

Material Espec. FORM TYS TUS YOUNG M Density

17-4PH AMS 5342 CASTING 120 KSI 130 KSI 28.5E3 0.282
KSI Lb/in3

Suggested manufacturing process

Due the geometry of the manifold I considered the best option for to manufacture the piece is casting
investment, I chose the material 17 – 4PH AMS 5342, there are some types of casting I chose the
investment method due these characteristics:

 The techniques of investment smelters are more respectful of the environment.

 The products are able to withstand high temperature and pressure.
 Intricate and complex shapes can be precisely designed.
 More precise and integrated approach for alloy foundries.
Results

Load Equivalent Equivalent Total Alternating life

stress strain deformation stress
500 psi 65 ksi 2.3 in/in 3.2 in
920.34 psi 121 ksi 4.2 in/in 5.9 in 60.38 ksi 1e6
1500 lbf 195 ksi 9.6 in/in 21.3 in
Stress strain graphic
Conclusions

 1500 psi pressure in enough for broke the exhaust manifold.

 With a pressure of 920 is possible to reach the plastic zone, where the deformation is
permanent.
 Pressures under 920 psi are not enough for reach yield zone, in that cases deformation will be
transitory just while the pressure is there, when the pressure fail the manifold will get the
original size and dimensions.
 We can see the behavior of the manifold at different pressures trough the stress-strain graphic.
 We can see the alternating stress and the life in the second graphic.
Appendix