Browse Publications Technical Papers 2019-26-0293

Test Correlation of an Exhaust System Durability Failure Using Enhanced CAE Approach 2019-26-0293

Durability of an exhaust system of an automobile is vital to it's overall performance as well as customer satisfaction. Current available CAE method using general modelling practices, though robust, offers a good scope to model critical details that have a definite bearing on prediction of its durability. In this work, an attempt has been made to capture all details such as effect of bolt pre-load on the rubber bushes/isolators, actual 3D model of the rubber bushes/isolators, material property based on measured load-deflection characteristics of the rubber bushes/isolators & contact interactions of mating surfaces that were apparently missing in the existing method. All such modelling enhancements were incorporated in the model, which was solved using non-linear solution technique. Different set of CAE results of modal, frequency response, harmonic fatigue, etc., analyses now correlate better with physical test results in terms of fatigue life as well as failure location for both failed and passed designs. This has resulted into not only capturing the physics of the system more accurately, but also better life/durability prediction that will eventually reduce the development time of such exhaust systems through minimal physical testing of prototypes.


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