Exhaust System Design and Development Management for Cars, SUV, MUV & FSAE
Exhaust System for Cars, SUV, MUV & FSAE
As shown exhaust system is placed
beneath the engine so ground clearance becomes very significant to avoid debris
hitting. Exhaust system components will be kept away from Intake system so that
intake air change density does not decrease. Also heat shield or cover will be
used for safety as driver sitting position is very near to exhaust system
component.
Exhaust manifold can be made from
nodular iron or cast iron, Stainless steel or heavy gauge steel. A flat
machined surface on the manifold fits against a mating surface on the exhaust
port area on the cylinder head. There
will be metallic gasket between exhaust manifold and cylinder head for proper
sealing. An exhaust pipe will be connected to exhaust manifold flange. Exhaust
headers will be tuned so that the exhaust pulse enters the exhaust manifold
between the exhaust pulses from the other cylinder, preventing interference
between the exhaust pulses. If the exhaust pressure pulses interfere with each
other the exhaust flow is slowed, causing a decrease in volumetric efficiency.
Specific exhaust manifold tuning creates a vacuum to help to draw exhaust out from
combustion chamber and improve fresh air charging because interference between
exhaust pulses is high for more than 3 cylinder engine.
Exhaust Pipe coming from cylinder
exhaust port can be merged in different way by changing pipe length and
diameter. Exhaust pipe is connected from the exhaust manifold to the catalytic
convertor. Exhaust pipe will be made by zinc plated steel with double wall
structure. Intermediate pipe is connected between exhaust pipe and the
catalytic converter.
Design Review :-
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Child
Part
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Requirement
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Material
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Manufacturing
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Cost
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Weight
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Life
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Design
Review
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Exhaust Manifold
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Burst Pressure 40 Bar,
Vibration 30 g,
Working Temperature
1000 ° C,
Surface Roughness Ra8
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Aluminum
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PDC, Machining
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A
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B
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A
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Exhaust Manifold with catalyst
will be parched and welding will be done on steel pipe to regulated pipe
length if required.
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Steel
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Machining
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B
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B
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A
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Gasket
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Working Temperature 1000 °
C, Leakage Pressure 30Bar
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Steel
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Machining
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A
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/
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C
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If no change is done in exhaust
pipe then same gasket from Yamaha R6 will be used. Otherwise same R6 gasket
will be machined to adjust shape for exhaust.
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Alloy
Steel
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Machining
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C
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/
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A
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Catalyst
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As per 2016 Emission Rule in UK
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Currently Fitted
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OEM
Knowhow
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A
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C
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B
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New R6 catalyst can be used as
per latest emission regulation 2016.
As currently fitted catalyst is
old it can cause back pressure or breach emission regulation however after
performance test old part can also be used.
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New R6 2016
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C
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A
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A
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Fastener
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Temp 1000 °C
30 G Vibration
100 N Load
No Rust
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M8 Class8.8
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Casting
Heat Treatment
Thread Making
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-
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-
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-
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As temperature, Vibration and
Chemical Reaction are high; it is suggest to use M10 Bolts.
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M8 Class10.9
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-
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-
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-
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M10 Class8.8
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-
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-
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-
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