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A modern exhaust system consists of various parts like manifold, flexible joint, catalytic converter, muffler and intermediate pipes. All these parts are integrated and serve the functional requirement of silencing the noise caused by high pressure exhaust gases leaving the engine and the level of emitting the toxic gases. The loads induced due to powertrain roll motion and the vibration characteristic from the ground and powertrain system is to be studied for the design of Exhaust system. The validation of exhaust system integrity is a challenging job. Thus the system, the design suggestions and iterations are studied using finite element approach to reduce product development time and cost. In this paper, an attempt is made to provide a design direction through finite element approach. However the scope of this paper is restricted only for the structural durability study of an exhaust system design.

This paper describes the use of a frequency based fatigue calculation to evaluate the fatigue life of a brake shield subjected to a dynamic load, where the loading and response are categorized using Power Spectral Density (PSD) functions. Traditionally fatigue damage is associated with time dependent loading, usually in the form of stress or strain. However, there are many design scenarios when the loading, or fatigue damage process, cannot easily be defined using time signals. In these cases the design engineer usually has to use a test based approach to evaluate the fatigue life of his component. In this study the brake shield is tested on shaker table using PSD loads as per SSTS. The FE approach is correlated with the physical test. The design is optimized and analyzed in FE to ensure it satisfies the design requirements thus reducing the product development cycle.