This document presents a sequential coupled thermal-structural analysis of an aftermarket exhaust manifold made of SUS 441L stainless steel. A finite element model of the exhaust manifold was created in ANSYS Workbench 15.0 to simulate the temperature distribution and related thermal stresses and deformations under operating conditions. The thermal analysis calculated temperatures ranging from 150°C at the engine interface to 38°C at outer surfaces. These temperature results were mapped to a structural analysis to determine stresses, strains, and deformations induced by thermal expansion. The analysis aimed to ensure the material and design were appropriate to withstand operating stresses and temperatures.
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1. Submitted in partial fulfillment of the requirements of MENG-5136G - Intro to FEA Graduate the FALL semester,
2014
Department of Mechanical Engineering Georgia Southern University
DETERMINATION OF THE SEQUENTIAL COUPLED THERMAL - STRUCTURAL
ANALYSIS AFTERMARKET EXHAUST MANIFOLD FOR A TRANSVERSE SI
ENGINE
Mosfequr Rahman
Associate Professor
Mechanical Engineering Department
Georgia Southern University
Statesboro, Georgia 30460 – 8045
mrahman@georgiasouthern.edu
Dwight Gustard
Graduate Student
Mechanical Engineering Department
Georgia Southern University
Statesboro, Georgia 30460 – 8045
dg01119@georgiasouthern.edu
ABSTRACT
This paper present the Sequential Coupled Thermal - Structural
Analysis to investigate the associated thermal stresses and
deformations under simulated operational conditions close to
the real situation on SUS 441L grade stainless steel for an
aftermarket exhaust manifold.. Analysis carried out by
reference environmental testing conditions in “room
temperature” standard conditions. The finite element analysis
software ANSYS Workbench 15.0 used to calculate the linear
steady state temperature distribution under the thermal field &
structural analysis. Thermal analysis calculates the temperature
distributions and related thermal quantities in an exhaust
manifold. Structural analysis takes inputs from thermal analysis
to calculate deformation, stress and strain. FEM analysis is
done by using tetrahedral element of first order and
convergence test is performed for structural load. The purpose
of this analysis is to ensure the appropriateness of material for
the defined design from the view point of serviceability of the
exhaust manifold. Selected details and results of the overall
investigation are presented and discussed within the framework
of this paper.
In addition to that, the impact of temperature effect on exhaust
manifold modal analysis is analyzed in this study. Firstly, the
temperature field is mapped from results processed in the
thermal analysis of the exhaust manifold. It was found that the
natural frequency of the manifold would not impact with the
frequency given off by the engine block. Those worst case
resonant conditions were calculated and are included in the
body of this paper.
INTRODUCTION
Automobile engines are the functional backbones that
contribute to and means of terrestrial transportation.
Researchers in the automotive field have rightfully emphasized