EXHAUST MANIFOLD

Foundry process to build an automotive exhaust manifold

LUIS FELIPE PINEDA SAUCEDO

13130073

06/02/2018

UNIVERSIDAD POLITECNICA DE CHIHUAHUA

Contents
Introduction .................................................................................................................................................. 3
The exhaust manifold is a part of the combustion internal combustion very important since this same
helps us that the engine gases come out after doing the compression generates high temperatures
which create pressure on the internal walls of the exhaust manifold and this causes different mechanical
efforts and deformations in the material, for this reason a material and process of invoicing will be taken
which will be cast and machined to give it a better finish ............................................................................ 3
Objective of Study ........................................................................................................................................ 3
Literature ...................................................................................................................................................... 3
Assumptions ................................................................................................................................................. 3
Free Body Diagram Schematic ..................................................................................................................... 4
Hand calculations ......................................................................................................................................... 4
Mesh Specifications...................................................................................................................................... 5
Results........................................................................................................................................................... 5
Graphic.......................................................................................................................................................... 6
Stress strain vs graphic ................................................................................................................................. 8
Conclusions ................................................................................................................................................... 8
Appendix....................................................................................................................................................... 9
Introduction

The exhaust manifold is a part of the combustion internal combustion very important since this same
helps us that the engine gases come out after doing the compression generates high temperatures
which create pressure on the internal walls of the exhaust manifold and this causes different mechanical
efforts and deformations in the material, for this reason a material and process of invoicing will be taken
which will be cast and machined to give it a better finish

Objective of Study

1. the force that causes manifold to escape reaches its ultimate stress
2. the pressure needed where the manifold will fail and where it is close to the plastic zone
3. the maximum effort supported by the exhaust manifold
4. find the fatigue that will have the manifold of escape and the life of this mechanical piece

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

Assumptions
Manufacturing Considerations:

1. The material was considered as Alloy 17-4PH is a precipitation-hardening, martensitic Stainless steel
used for parts requiring high strength and good corrosion and oxidation resistance up to 600EF.

2. The alloy is available in all product forms, Manufacturing Considerations — 17-4PH is readily forged,

3. The material that was considered for the manufacture of the exhaust manifold has the specifications
AMS 5643 Bar, forging, and ring
4. With the manufacture of this exhaust manifold, another manufacturing process will be taken into
account, which will be a finishing machining to have a greater mechanical resistance.

5. Best machinability is exhibited by Conditions H1150 and H1150M. A dimensional contraction of

0.0004 to

0.0006 And 0.0008 to 0.0010 in. /in. occurs upon hardening to the H900 and H1150 conditions,
respectively.

Free Body Diagram Schematic

Hand calculations

Stress of Von-Mises

𝜎𝑥 + √𝜎𝑥2 + 4(𝜏𝑥𝑦
2 2
+ 𝜏𝑥𝑧 )
𝜎1 =
2

Thick-walled cylinders
 𝑝(𝑏2 +𝑎2 ) 𝑓
𝜎1 = 𝜎=𝑎
𝑏2 −𝑎2

𝑝𝑎2
𝜎2 = 𝑏 2 −𝑎2

Mesh Specifications
Node Elements Method
77575 38776 Hexa dominat

Results
Load(F) Material Young TYS TUS Stress Strain Deformation
Modulus

5000 PSI 17-4PH 28500 PSI 105000 PSI 135000 PSI 1.161E6 PSI 1.0255E6 PSI 0.37318 IN
2000 PSI 17-4PH 28500 PSI 105000 PSI 135000 PSI 4.646E5 PSI 4.1019E5 PSI 0.14927 IN
1500 PSI 17-4PH 28500 PSI 105000 PSI 135000 PSI 3.4848E5 PSI 3.0765E5 PSI 0.11195 IN
Graphic
Stress strain vs graphic

5000 psi

2000 psi

1500 psi

Conclusions
To conclude with this analysis that was made in ansys many points were taken into account, as was the
manufacturing process for its manufacture. In this case the manufacturing process that was chosen for
the manufacture of this automotive product that is exhaust manifold I decide to do it forged and taking
into account all its parameters to be able to obtain a piece of quality and in the same way we looked for
it to know the life that this piece would have used and why they made several calculations to determine
each one of these point, also worked in the ordinary that was in submitting this design to different
mechanical tests of strain and deformation to be able to be clear if the material and process chosen for
this piece is the right mechanical.

Appendix

Pressure 5000 psi

Pressure 2000 psi
Pressure 1500 psi