See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/296217423

The Impact of Temperature Effect on Exhaust Manifold Thermal Modal Analysis

Article in Research Journal of Applied Sciences, Engineering and Technology · August 2013
DOI: 10.19026/rjaset.6.3792

CITATIONS READS
21 679

5 authors, including:

Zhien Liu
Wuhan University of Technology
77 PUBLICATIONS 396 CITATIONS

SEE PROFILE

All content following this page was uploaded by Zhien Liu on 24 March 2022.

The user has requested enhancement of the downloaded file.

Research Journal of Applied Sciences, Engineering and Technology 6(15): 2824-2829, 2013
ISSN: 2040-7459; e-ISSN: 2040-7467
© Maxwell Scientific Organization, 2013
Submitted: January 22, 2013 Accepted: March 02, 2013 Published: August 20, 2013

The Impact of Temperature Effect on Exhaust Manifold Thermal Modal Analysis

1, 2
Bin Zou, 1, 2Yaqian Hu, 1, 2Zhien Liu, 1, 2Fuwu Yan and 1, 2Chao Wang
1
School of Automobile Engineering, Wuhan University of Technology,
2
Hubei Key Laboratory of Advanced Technology of Automotive Parts, Wuhan 430070, China

Abstract: The impact of temperature effect on exhaust manifold modal analysis is analyzed in this study. Firstly, the
temperature field is mapped from the CFD software and then heat conduction process is analyzed in FEM software
with the temperature field boundary conditions. At last the modal analysis that considers temperature effect is done.
The frequency and vibration mode between cold modal and thermal modal’s are compared. The result shows that
temperature has a great influence on the manifold mode and it is very valuable to product design.

Keywords: Exhaust manifold, Finite Element Method (FEM), temperature field, thermal modal analysis

INTRODUCTION (2006) considering a flat plate as the object of research,

the analyses of structural transient temperature field and
Modal analysis is used to study the inherent characteristic of structural vibration are presented with
dynamic characteristics of a system. Natural frequency the conditions of thermal load. Their calculation results
can show that the structure can produce resonance show that transient heating has a serious effect on the
under some certain excitation frequency. Vibration characteristic of structural natural vibration. Yang and
mode is able to show the structure deformation Guo (2009) make an engine piston thermal field
corresponding to each natural frequency. The exhaust simulation by ABAQUS software and take the pre-
manifold is close to the engine part in automotive stress and load into account. The pre-stress include
exhaust system, because the cylinder discharge gas thermal stress, mechanical stress and the coupling stress
temperature can reach 800°C above, the tail gas heating and the mechanical loads include gas pressure, lateral
effect is obvious. Because the thermal stress that tail force and mass inertia load. At last, piston fatigue
gas heating caused can be as high as hundreds of Mpa, analysis was done by stress results and the work is very
it can also lead to thermal fatigue and cause structural valuable to product design. Yang et al. (2011) build an
fracture. Temperature has great influence on material FEM model for the engine barrel tube and obtains its
mechanical properties, so it is necessary to take the thermal vibration modal parameters, the result validates
influence of the temperature pre-stress on exhaust the design of the corrugated tubes is rationality. The
manifold vibration characteristics into account. calculation result show structure temperature will
The traditional modal analysis technique is linear increase evidently so as to have a serious effect on the
modal analysis based on linear model. Linear theory characteristic of structural natural vibration during the
ignores the actual system inherent nonlinearity, such as process of heating and offers some reference for the
material nonlinearity, so sometimes it may cause dynamical response analyses and structure design of
qualitative theoretical errors, especially in resonance tank gun barrels.
case. It can come to some other modes except the linear This study taking the exhaust manifold as the
mode; in this way, the linear modal analysis is unable to research object, the geometrical model is meshed in
deal with nonlinear system modal problem effectively. HYPERMESH software which is efficient in finite
Therefore, approximate analysis methods are usually element grid partition and then the temperature effect
taken, one of the most typical methods is the pre- on the modal result is analyzed by the couple of
stressed modal analysis method which considering the ABAQUS and STAR CCM+ software. The influence of
influence of material nonlinearity, geometrical temperature on structure natural vibration
nonlinearity, contact nonlinearity or loading on characteristics is studied. ABAQUS is engineering
structure analysis, to deal with the actual nonlinear simulation of finite element software and STAR CCM+
engineering system simulation. A variety of researches is Computational Fluid Dynamics (CFD) analysis
have been working on this area. Such as Shi and Yang software. This study mainly considers the uneven

Corresponding Author: Yaqian Hu, School of Automobile Engineering, Wuhan University of Technology, Wuhan 430070,
China
2824
 Res. J. Appl. Sci. Eng. Technol., 6(15): 2824-2829, 2013

Fig. 1: Thermal modal analysis process

temperature distribution which leads to material the material elastic modulus and lead to the initial
nonlinearity, temperature pre-stress and bolt pre- stiffness matrix changes. Take the structure initial
tightening force impact on modal analysis. stiffness matrix that after heating up as Shi and Yang
(2006):
Basic analysis process of thermal modal analysis:
The thermal modal analysis considering the influence K T = ∫ B T DT BdΩ (1)
of the temperature and stress fields is based on thermal Ω
analysis and structure analysis (Shi and Zhou, 2006; Ji
et al., 2010), the basic analysis process of thermal where,
modal analysis is as follow and the flow chart is shown B = Geometric matrix
in Fig. 1: D T = Elastic modulus which is related to material
elastic matrix E and Poisson's ratio μ
• Through the fluid analysis in STAR CCM + and
the coupling with ABAQUS, the wall temperature On the other hand, because the thermal stress
and heat transfer coefficient are mapped to caused by temperature gradients, additional initial stress
ABAQUS grid. stiffness matrix is needed besides structure stiffness
• Take the mapping result as the analysis condition matrix. The structure initial stress stiffness matrix is:
in the heat conduction analysis by ABAQUS.
• Take the temperature field result of heat Kσ = ∫ G T ΓGdΩ (2)
conduction analysis as load and combine with the Ω
temperature changed material physical properties
and mechanical performance parameters to solve where,
structure thermal stress. G = The shape function matrix
• Take the thermal stress result as initial stress Γ = Stress matrix
condition and consider the heterogeneity of
temperature field, combine with the temperature In summary, the structure thermal stiffness matrix is:
varied material physical and mechanical properties
(density, elastic modulus, coefficient of linear
K = K T + Kσ (3)
expansion and Poisson's ratio), to solve the
structure thermal mode.
Modal analysis theory of temperature effect: The
STRUCTURE THERMAL STIFFNESS basic equation for typical un-damped modal analysis is
AND MODAL ANALYSIS THEORY classic eigenvalue problem. According to mode theory,
the structure will typically be seen as a system
Structure thermal stiffness theory: The temperature constituted by the mass point, rigid body and damper
effect on structure stiffness is mainly from two aspects. and discrete it as finite number of elastic coupling rigid
On the one hand, the heating up temperature can change bodies. Therefore, an infinite multi-degree freedom
2825
 Res. J. Appl. Sci. Eng. Technol., 6(15): 2824-2829, 2013

system turns into limited multi-degree freedom system.

When the linear time-invariant system requirements are
met, the system general motion mathematical model
can be expressed as:
• •
M x + C x + Kx = f (t) (4)
Fig. 2: Finite element model
where, 140
M, C, K : The mass matrix, damping matrix and
stiffness matrix 120
x : The exhaust pipe vibration displacement 100
vector

E (GPa)
80
f (t) : The exhaust pipe load vector
60
Modal analysis method is to replace the physical
40
coordinates of modal coordinates that each principal
mode corresponded, so that the differential equation 20
decoupling to be independent differential equations in 0
order to obtain the system modal parameters. The 293 373 473 573 673 773 873 973 1073 1173
vibration of the engine exhaust pipe is a slight T (K)
vibration, basically belong to linear time-invariant
systems, it can be assumed that M is a constant matrix. Fig. 3: Temperature varied young modulus
The structural damping of exhaust pipe has little effect
on the natural frequencies and therefore do not consider 1.75
the external load and damping. Thus Eq. (4) simplifies 1.70
Expantiom (e-5/k)

to: 1.65
1.60
K − ω 2 MΦ = O (5)
1.55
where, 𝑀𝑀 − ∫Ω 𝜌𝜌𝑁𝑁 𝑇𝑇 𝑁𝑁𝑁𝑁Ω is the structure overall quality 1.50
matrix. 1.45
When the order of matrix K and M is n, the ω2 in 1.40
formula (5) is the n times real coefficient equation and 1.35
the system degree of freedom vibration characteristics 293 373 473 573 673 773 873 973 1073
(natural frequencies and mode shapes) problem is to T (K)
solve the matrix eigenvalue ω.
Fig. 4: Temperature varied thermal expansion coefficient
FINITE ELEMENT ANALYSES
Constraints and load description: It is set to be
Finite element model: The exhaust manifold finite normal displacement constraints (Y direction) on
element model is shown in Fig. 2, use HYPERMESH to exhaust manifold inlet flange end face and radial
do the mesh generation work, the grids of the inner and displacement constraints (X, Z direction) in the inlet
outer wall of the exhaust manifold are corresponding flange end bolt holes.
with fluid analysis grids for internal and external wall Simplify the load acting on the exhaust manifold,
temperature field boundary coupling between software. such as simplify the connection relationship of the bolt
Use tetra elements with local region refined, the amount and the circular hole for the reference point and the
of elements was about 550000. distribution coupling of the hole inner surface
constraint and apply bolt pre-tightening force.
Material properties: The structure material is
Temperature load is set as a predefined field through
QTANi35Si5Cr2. It’s Poisson's ratio is 0.283 and
the heat conduction results.
density is 7450 kg/m3. The specific heat capacity,
thermal conductivity, Young modulus, thermal In the thermal modal and cold modal analysis, cold
expansion coefficient are different according to the modal analysis means the modal analysis with constant
temperatures. Build temperature changed material field material properties parameters under room temperature
in ABAQUS as material properties (Yang and Guo, and whereas thermal modal analysis means modal
2009). The material properties are shown in Fig. 3 analysis with temperature pre-stress and with
and 4. temperature dependent material properties parameters.
2826
 Res. J. Appl. Sci. Eng. Technol., 6(15): 2824-2829, 2013

FINITE ELEMENT ANALYSIS AND RESULTS The first three order vibration shape diagrams of
cold modal and thermal modal in free state are shown in
Heat conduction analysis and temperature field Fig. 6:
result: Thermal boundary conditions of heat Comparison can be seen in the vibration shape
conduction is the inside and outside wall temperature diagrams that in free state vibration shapes of cold
and convective heat transfer coefficient mapping file modal (room temperature) and thermal modal are
that ABAQUS and STAR CCM+ coupled. The outer mainly torsion, as can be seen from the vibration shape
wall and the air convective heat transfer coefficient are that the first three orders of cold modal are mainly
set for 13.5, ambient temperature for 360 K. torsion in X direction and the first order of thermal
Temperature field result of thermal conductivity
modal is mainly torsion in X direction, the next two
analysis is shown in Fig. 5, unit is K.
orders are mainly torsion in Y direction.
Thermal modal analysis and cold-modal analysis First three order vibration shape diagrams of cold
results: The cold modal frequencies are as follows in modal and thermal modal in constrain state are shown
Table 1 and heat modal frequencies are shown in in Fig. 7.
Table 1. It can be seen from the diagrams that in constrain
Table 1 data shows that: the cold modal (normal state, vibration shapes of cold modal (room
temperature) and the thermal modal in a free state and temperature) and thermal modal are mainly bend. as
the constrain state, the first order and higher order can be seen from the vibration shape that the first order
frequencies vary differently and the thermal modal of cold modal is mainly bend in Z direction and the
frequencies with temperature effect decreased as a next two orders are mainly bend in X direction, the first
whole. With temperature pre-stress and bolt pre- order of thermal modal is mainly bend in Z direction,
tightening force and the same boundary condition, the the next two orders are mainly bend in X direction.
exhaust manifold thermal modal frequency is lower Exhaust manifold temperature effect is mainly
than the cold modal frequency of the same order and reflected in two aspects. On the one hand, the
with the increase of order, the reduction is larger. The temperature reduce the material stiffness and uneven
influence of temperature on every modal frequency is temperature distribution lead to material nonlinearity;
different, but the total effect is lowering. on the other hand, the thermal stress that the

Fig. 5: Temperature field nephogram

Table 1: Cold and thermal modal frequency

Frequency (Hz)
------------------------------------------------------------------------------------------------------------------------------------------
Cold modal (normal temperature) Thermal modal
---------------------------------------------------------------------------- ------------------------------------------------------------
Order Free state Constrain state Free state Constrain state
1 1392.5 1985.2 463.73 1352.0
2 1989.4 3386.4 1053.80 2285.4
3 2277.1 4423.6 1079.00 3011.2
4 3451.1 4892.5 1517.30 3354.1
5 3794.2 5877.6 2051.50 4021.7
6 4067.4 6741.8 2262.60 4612.9

2827
 Res. J. Appl. Sci. Eng. Technol., 6(15): 2824-2829, 2013

Fig. 6: The first three order vibration shape diagrams of cold modal and thermal modal in Free State

Fig. 7: The first three order vibration shape diagrams of cold modal and thermal modal in constrain state

temperature generated can be seen as pre-stress and will thermal modal analysis is 473.73 Hz and the cold
reduce structure’s bending and torsional stiffness, modal’s lowest natural frequency is 1392.5 Hz, both
therefore, the structure natural frequency will be lower meet the requirements to avoid the resonance between
under the temperature pre-stress (Yang et al., 2011). exhaust manifold and the engine or other parts.
The exhaust manifold mainly motivated by the
road and engine, generally the road incentive is about CONCLUSION
30 Hz and the engine inventive is more than 200 Hz, so
the design frequency of exhaust manifold should be In this study, a basic analysis process of the
greater than 270 Hz. It can be seen by analyzing the exhaust manifold thermal modal analysis is built. And
results that the lowest order natural frequency of the temperature pre-stress is applied on the exhaust
2828
 Res. J. Appl. Sci. Eng. Technol., 6(15): 2824-2829, 2013

manifold modal by the coupling of ABAQUS and REFERENCES

STAR CCM+, then the exhaust manifold thermal mode
is analyzed with bolt pre-tightening force by ABAQUS Ji, K.X., H.W. Song and C.H. Huang, 2010. The
and comes to the conclusion that: influence of temperature field and stress field on
active cooling engine vibration modal. Proceeding
• Heating cause the nonlinear change of material of the 3rd Hypersonic Technology Academic
Conference on CSTAM-2010-0039, Wuxi.
physical property and generate thermal stress, the
Shi, X.M. and B.Y. Yang, 2006. Temperature field and
combined effects of both make the structure’s mode analysis of flat plate with thermal
natural frequency decline after heating. environment of transient heating. Comput. Aided
• By comparing the cold modal (room temperature) Eng., 15(4): 15-18.
with thermal modal frequencies and vibration Shi, Y.P. and Y.R. Zhou, 2006. ABAQUS FEA
shapes, the results show that the temperature pre- Examples and Explanation: Mechanical
stress has different effect on the exhaust manifold Engineering Press, Beijing.
structural modes, it lowers the frequency and the Yang, H.G. and L. Guo, 2009. Simulate study for piston
effect on the torsional rigidity is bigger than on heat-mechanical strength. Proceeding of the China
Internal Combustion Engine Combustion Energy-
bending rigidity with the temperature increasing.
Saving and Purification Branch Academic
Conference (CSICE2009-013).
Thus, in the exhaust manifold design and Yang, Z.B., H. Yang and D. Zhou, 2011. Thermal
evaluation, the effect of temperature on material modal analysis of engine inlet. Aeronaut. Comput.
mechanical properties should be taken into account. Tech., 4(15): 65-71.

2829

View publication stats