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In spite of the changes in vehicle performance, one of the current challenges is to get components applicable to different vehicles with no changes in the project. Simulations made with specific numerical programs enable this process of unifying components, for different platforms, to be applied to the exhaust system. The projects proposed, based on the results obtained with the simulation programs, were tested experimentally. It was proven that the results of the simulation proposals correlated to the experimental results. This ultimately provided simplification to the project, with gains in logistics and productivity. Besides the technological process involved, possibilities to reduce costs can also be considered.

The durability certification is one of the critical paths of a mass production vehicle project. For structural components, the development and the execution of experimental tests supported by finite element method (FEM) became mandatory for implementation time reduction, especially when on-board diagnoses (OBD) legislation turns even small cracks in severe structural failures. This job aims to show a simulation method of structural efforts in an exhaust system on a test bench. The exhaust pipe is previously analyzed with FEM and the critical points are instrumented with strain gage in vehicles. The strains are measured and its values reproduced in a dynamometer bench using a shaker with adjustable amplitudes. Therefore, difficulties to reproduce temperature and strain were overcome and the test shows repeatability. The variation of shaker device amplitude makes it possible to define the life cycle curve of the part.