CAREER EPISODE 1 DESIGN AND ANALYSIS OF DUAL-MODE MUFFLER EXHAUST SYSTEM. 1.1 INTRODUCTION Univesity: Karunya University Location: Date; Spain + Project type: Academic + Role: Team leader Karunya University Department of Mechanical Engincering Supervisor Figure 1: Orgenogra 12 BACKGROUND 124 ‘The exhaust system in the automobile industry is a mechanical system that allows the transfer of reaction gas produced in the Vehicle system to the outer surrounding. ‘The exhaust system consists of different components which are a catalytic converter, ounffler, resonator, and exhaust manifold. ‘A muffler in the exhaust system is used to reduce the noise produced by the exhaust of the IC engine, In today’s time, one of the major contributors to noise pollution is exhaust sound produced by the automotive vehicle. ‘Therefore, there has been a huge development in trends and technology in the muffler system to avoid unwanted noise. A dual-mode automotive muffler is one of theexhaust systems used in the automobile industry that reduces the noise at the top rate by reducing the exhaust resistance when the engine is running at a high speed ‘The main focus of the project was to design and analysis of dual-mode muffler exhaust system that helps to reduce exhaust resistance anc noise in the automobile industry. Mild steel was selected as the material for the primary and secondary mufflers and straight tubes. Copper was used for the inlet and outlet pipes. SolidWorks were used to design dual-mode muffler exhaust system and other associated tubes were also developed and assembled, Three models were designed by varying the distance between the sub-muffler and main-muffler by 150 mm, 200 mm and 250 mm. Later, the 3D models were imported to ANSYS software where CFD analysis of the flow field for the muffler exhaust system was done, The results were obiained in form of pressure contours and velocity contours. The model 2 was selected as the best model because the model has highest flow velocity. 1.2.2 OBJECTIVES ‘The prime intention was to design and perform a numerical analysis of a dual-mode muffler exhaust system for the automobile industry. The other objectives were ‘¢ To reduce the pressure, drop and deduct the production of gas in the exhaust ‘© To obtain the best design as per the outcomes of analysis, 1.2.3 DUTIES ‘© To review the theoretical background of exhaust system through various journal articles, and research papers ‘* To select the suitable materials, components, and required software, ‘© To prepare the 3D model of a dual-mode muffler exhaust system on SolidWorks. ‘© To perform the analysis of a model on ANSYS. ‘* To observe the outcomes of analysis and make proper conclusion of the project. 13 PEA 134 1 initiated my project by reviewing the research papers. journals, and articles related to the automobile exhaust system. Atfirst,I studied different types of the automobile exhaust system and their properties. Afterward, | learned about the internal flow and pressure loss characteristics of the exhaust. I explored the governing equation needed for the flow field analysis of automobile exhaust on which I studied mass & momentum conservation equations and flow control equations. [learned the design procedure for designing dual-mode automotive mufflers. Then, I studied design and simulation tooks to design and perform the CED analysis ofthe exhaust system. 132| researched the available material forthe design of the automatic dual-mode automotive muffler. J analyzed the material properties, and its strength in regards to the availability, budget, and requirement. I surveyed the market and collected the materials needed to develop the automobile exhaust. I selected to design three models by varying the distance between the sub-muffler and ‘main-muffler by 150 mm, 200 mm and 250 mm. selected the two cylinders of material mild stect as primary and secondary mufflers and straight tubes of mild steel connecting the cylinders Similarly. 1 used two other copper pipes having small holes on their surface for the gascous flow in the system acting as inlet and outlet respectively. I then selected the springs and values required for the assembly of the dual-mode exhaust system. I also specified the rotational speed of the engine as per the requirement. 133 ‘After I selected the material for developing the dual-mode exhaust, 1 developed the 3D model of the muffler in SolidWorks. 1 used various tools and features which were available in the SolidWorks librury to design the muffler and pipes. | employed a sketch tool to draw circles, and lines and then used extrude tools to meet the required length dimensions, After that, designed the inlet pipe, I designed the two outer shells of the muffler by extruding the circle to the required length, Further. | designed the outlet pipe Finally. | inserted the pipe through the center of two shells, connecting the two cylinders. At last, I attached the value and the spring to the exhaust system. 1 created the all three designs of the muffle flowing the similar procedure by varying the distance between the sub-muffler and main-muffler by 150 mm, 200 mm and 250 mm. igure 2: foe 1,10 eta eters ered maFieue 7: Secthonal View 0 Figure 8: Wire frame view of ede 1134 1 imported the 3D mode! of the dual-mode exhaust system to the ANSYS workbench for the simulation. | then assigned the fluid and solid portions in the model as well as allocated the properties of the material in the model, Later, I meshed the exhaust model dividing it into several elements and nodes. I used the simple algorithm to solve the governing equation and the standardturbulence K-e model to ran the simulation, Moreover, 1 applied the velocity entrance at the inlet of the pipe and pressure with a value of Oat the outlet. I set the no-slip boundary condition to the ‘model. Then, | initiated the solver unit to run the simulation. Finally, 1 ran the simulation program. successfully and I observed the results in the form of pressure and velocity contours. ere a gore 11: Mesed mel of meltae J Fire 16; Sectional mask of he 135 Afier tie mumerical simulation was completed for both cases of valves open and closed, | observed allof the outcomes. For the case 1, [observed the maximum pressure of 6,606 e“*"Pa, turbulence kinetic energy of 4.266 e% ni'/s?, velocity of 6.954 e"" ms, velocity vector at main muftler of 7.098 e" mis, velocity vector contour at sub muffler of 7.098 e! m/s, Velocity vector of 7.098 "ins. For the ease 2, | observed the maximum pressure of 6.782 e"° Pa, turbulence kinetic energy of 4.114 e% mijs?, velocity of 7.034" mis, velocity vector at main muffler of 7.181 e!" mvs, velocity vector contour at sub muffler of 7.181 e"" mis, Velocity vector of 7.181 nv. For the case 3, | observed the maximum pressure of 6.891 e Pa, turbulence kinetic energy of 4.274 e*®” m/s", velocity of 7.016 e®" mis, velocity vector at main muffler of 7.162 ¢°* mvs, velocity vector contour at sub muffler of 7.162 ¢! m/s, Velocity vector of 7.162 ¢"nvs, I concluded that the case I ie... model 2 with the 150 mm distance between the muffler as the best design because the flow velocity was maximum, which results in the minimum airflow resistance.Table 1: Outcomes wats ‘Case | Pressure Pa | Turbulence | Velocity, | Velocity | Velocity | Velocity kinetic mis vectorat | vector at | vector, nergy m/s? main sub ms muffler, | muffler, ms ms T 66 | 42660 | 654” | 709Re” | 709Re! | 709Re™ "Pa mis 2 67 | atise® | Toa” | 7awie™ | 7181" [71e1e™ 3 oaare™ | 4a74e™ | 70168 | 71626" | T1620" [7.1627 Case eer e Pinteee At Baths ke Fleur 20: Veloce vector conor athe main miler Fleur 21 Velocity veto counoarar sub muflera Fest sane inet Figure 2: Vloty vector igure 25: Presse contour case 2Figure 26: Velotty vetor contour a mab mae, case 2 intl Figure 27: Vlotty vector contour sub elere.., meth : cmd al Figure 28 Veli vector igure 29 Presse conto, ave 5Figure 32: Velocity vetor contour mab mae, case 3 e478 inetd Figure 33: Velo vec couner ai sub me, case 3a ba he a 14 TECHNICAL PROBLEMS AND SOLUTIONS, 14d During the meshing of the dual-mode exhaust model, used the fine mesh to the mode! to find the precise result. Later on, I faced a problem in the meshing of the model as it took lots of time and later failed to generate the mesh. Then, I studied the issues and found out that the ANSYS work ‘module for meshing was not able to generate the fine mesh at the edges and curved surface of the exhaust model. Then, I manually assigned the size ofthe mesh by reducing the number of elements, and nodes. After many hit and trial methods, I generated the mesh of the dual-mode of exhaust solution successfully which was further used for the numerical simulation and analysis. 142 | developed the velocity contour and pressure drop contour at the center plane of the dual-mode exhaust system, At first, I wasn’t able to obtain the velocity contour result perfectly as the simulation was interpreted in middle. Then, | discussed! the issue with my supervisor. Afr the rounds of discussion, I found the SIMPLEX method was useful for systems having two variables’ inequalities and the method had good performance on swirl flow. Then, I concluded to perform the simulation by using the solution method of the SIMPLE algorithm than using the SIMPLEalgorithm. Then, I used the SIMPLE algorithm to run the numerical simulation of the dual-model exhaust model. I successfully ran the simulation and obtain the pressure drop contour and the velocity contour successfully 1.5 CREATIVE ACTIVITIES ‘optimized the model design by developing the secondary muffler using the mirror entity function in SolidWorks which assisted in reducing the time and proper alignment of the model. I used SIMPLE algorithm 0 run the numerical simulation of the dual model exhaust for obtaining the perfect ofthe velocity and pressure contour. enhanced the mesh size For decreasing the simulation time. 1.6 PROJECT MANAGEMENT AND CODES. I was appointed as leader of team. During this time, 1 used to have regular meetings with my supervisors. I maintained good relationships with my teammates. I used to help my teammates when they faced problems during the project. I managed and developed the strategies for the effective implementation of the project to meet the goals and objectives. I divided the work and distributed the work among team members and completed the work on time. I madle proper interaction with all of the team members for solving the issue faced during the project execution. also interacted with supervisor if the degree of issue was high. I formulated different plans for solving the issues. I compiled all of the completed works and made final report of the project. I ereated the CAD design of the muffler referring to ICS 35.240.10. learned more on the transport exhaust emission through ICS 13.040.50. 1.7 SUMMARY Design and analysis of the dual mode mutfier exhaust system was completed successfully. The proper design resulted in reducing the pressure, and the production of the gas exhaust was deducted. The model with 200 mm of the m distance between the sub muffler and main muffler ‘was selected as the best design, For meeting project target, three designs were made by varying. the distance between the sub-muffler and main-muffler by 150 mm,200 mm and 250 mm, Design ‘was created in SolidWorks and CED analysis was performed in ANSYS. The outcomes revealed that the model 2 had the highest velocity of 7.181 e”" m/s. hence, the model 2 was selected as the best design among three In addition to this, I improved my interpersonal qualities like problem-solving skills, and communication skills during the project. Further, I enhanced my design skills and skills for operating design and analysis software. I enhanced my project management skills and skills related to the time management