MECHANICS OF MATERIAL

CEP

Submitted to
Sir Kashif Ishfaq
Submitted by
Bilal Fiaz (2019-IM-11)
Abdul Rehman (2019-IM-37)
Table of Contents
1 Title.......................................................................................................................................... 4
2 Objective .................................................................................................................................. 4
3 Introduction ............................................................................................................................. 4
3.1 Car silencer ....................................................................................................................... 4
3.2 Parts of car exhaust system .............................................................................................. 4
3.2.1 Exhaust Manifold ...................................................................................................... 5
3.2.2 Exhaust pipes ............................................................................................................ 5
3.2.3 Catalytic converter .................................................................................................... 5
3.2.4 Muffler ...................................................................................................................... 6
3.3 Combustion produced ...................................................................................................... 6
4 Materials .................................................................................................................................. 7
5 Factors for choosing material .................................................................................................. 7
5.1 Young modulus ................................................................................................................ 7
5.2 Density ............................................................................................................................. 7
5.3 Fatigue strength ................................................................................................................ 7
5.4 Thermal conductivity ....................................................................................................... 7
6 Properties of materials ............................................................................................................. 7
7 Choose material ....................................................................................................................... 8
7.1 Reasons for choosing stainless steel................................................................................. 8
8 New invention (Optimization) ................................................................................................. 8
8.1 The Smoke Absorber ........................................................................................................ 9
8.2 Purpose ............................................................................................................................. 9
8.3 Structure ........................................................................................................................... 9
8.4 Function ............................................................................................................................ 9
9 Conclusion ............................................................................................................................. 10
10 References .......................................................................................................................... 10

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List of figures
Figure 1 Car silencer ...................................................................................................................... 4
Figure 2 Parts of car silencer ......................................................................................................... 4
Figure 3 Exhaust manifold .............................................................................................................. 5
Figure 4 Exhaust pipes .................................................................................................................... 5
Figure 5 Catalytic converter............................................................................................................ 6
Figure 6 Muffler .............................................................................................................................. 6
Figure 7 Smoke Absorber Phenomenon ......................................................................................... 9

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1 Title
Material selection for car exhaust system and optimization.

2 Objective
 To learn about car exhaust system and its function
 Select different materials for car exhaust system.
 Finally select best materials under consideration of some properties.

3 Introduction
3.1 Car silencer
 It is used to reduce noise due to internal combustion
 It also reduced harmful gases like CO and SOx (SO2, SO3) [1].

Figure 1 Car silencer [13]

3.2 Parts of car exhaust system

The following parts of car exhaust system given below

 Exhaust manifold
 Exhaust pipes
 Catalytic converter
 Muffler
 Tail pipe [1]

Figure 2 Parts of car silencer [14]

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3.2.1 Exhaust Manifold
 It is upper end of exhaust system of an engine.
 The primary work of exhaust system to receive burned gases from the engine and it is
directly attached to engine.
 It burns that types of fuel which are ineffectively burned by engine and flues down to main
exhaust system [1].

Figure 3 Exhaust manifold [15]

3.2.2 Exhaust pipes

It is used to guide reaction exhaust gases away from combustion inside the engine. The whole
system carries burnt gases from car engine and it include many pipes [1].
3.2.3 Catalytic converter

Figure 4 Exhaust pipes [16]

The device that convert three harmful compounds to harmless compound in exhaust system and it
used catalyst as a converter.
These compounds are
 Hydrocarbons - in the form of unburned gasoline.
 Carbon monoxide -formed by the combustion of gasoline.
 Nitrogen oxides - created when the heat in the engine forces nitrogen in the air to combine
with oxygen [1]

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 Figure 5 Catalytic converter [17]

Using catalyst
 Reduction catalyst
 Platinum
 Rhodium
 Oxidation catalyst
 Platinum
 Palladium
3.2.4 Muffler
 It is used to decrease the amount of noise produced by the exhaust system of internal
combustion engine.
 The main purpose of muffler is to absorb the noise of exhaust system gases. It is composed
of outer shell, inner plates, end plated and many other components.
 It contains simple set of tubes that finely tuned to reflect the sound waves produced by an
engine so that they cancel each other out [1].

Figure 6 Muffler

3.3 Combustion produced

 In a spark ignition engine, during an intake process the air mixed with fuel and then
introduced in the cylinder.
 Combustion produced in engine when piston compress air-fuel mixture.
 During power stroke gases pushes piston when expansion of combustion produced [2].

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4 Materials
Materials that used in car exhaust system given below
 Nickle chromium alloys
 Cast iron
 Stainless steel (Ferritic stainless steel)

5 Factors for choosing material

 Young modulus
 Density
 Fatigue strength
 Thermal conductivity
 Temperature
 Cost
5.1 Young modulus
 Ratio of stress to tensile strain
 If young modulus is high than material is good
𝝈
E=
𝜺
5.2 Density
It is the ratio of mass to volume [3].
m
ρ= V

5.3 Fatigue strength

 It is highest stress that can material bear for define numbers of cycles without breaking.
 It is affected by environment such as corrosion.
 The possible amount of stress that can applied on the material at define number of cycles
without fracture is fatigue strength [4].
5.4 Thermal conductivity
The thermal conductivity of a material is a measure of its ability to conduct heat [5].
𝑄𝑑
𝑘 = 𝐴 ∆𝑇

6 Properties of materials
Materials Nickle chromium alloys Cast iron Stainless Steel
Composition 20 % chromium 2.9-4.0% C 2.9-4.0% C
80 % Nickel 1.5-2.6% Si 1.5-2.6% Si
0.5-0.7% 0.5-0.7% Mn+ traces
Mn+ traces of S, P of S, P

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 Young Modulus 150-245 80- 150 190-203
𝝈
E= 𝜺 (GPa)

Density (kg/m3) 7750-8650 6900-7350 7850-8060

Fatigue 600 263 360

Strength (MPa)

Thermal 8-17 40-72 14-17

conductivity
(W/m.K)

Melting Point 1200-1436 1130-1376 1371.1-1421

(°C)

Cost (PKR/Kg) 3200 160 508 [6] [7] [8]

7 Choose material
The material that chosen for car exhaust system is stainless steel (Ferritic stainless steel).
7.1 Reasons for choosing stainless steel
 The high temperature of gases passing through the exhaust system is due to the high
melting point.
 The high temperature of exhaust manifold is about or above 800 oC and for muffler is 400
o
C.
 It oppose the corrosion that effect the material.
 Hot water vapor of exhaust gas considering oxidation.
 It has low density, which can improve economy of fuel.
 The vibration is low in the material due to high young modulus.
 It allow spreading of heat along the whole component due to high thermal conductivity.
 It resist crack propagation from an existing crack due to high fracture toughness.
 It has high resistance to thermal fatigue considering high temperature of above 800 oC for
exhaust manifold and above 400 oC for muffle box.
 High yield strength to withstand the thermal stresses

8 New invention (Optimization)

The new invention (optimization) is “The Smoke Absorber”

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8.1 The Smoke Absorber
Exhaust
pipe
Smoke
absorber

Connecting Organic
pipe after CaCO3 + solvent Pump
muffler H2O (toluene circulation
110oC) connect to

Figure 7 Smoke Absorber Phenomenon

8.2 Purpose
To control the air pollution and prevent greenhouse gases to escape into the atmosphere.

8.3 Structure
 This connected after catalytic converter and muffler.
 There is a pump connected to drive shaft that circulate the liquids over inclined surfaces,
and a tray connected where these liquids are present.
 Finally, minute amount of gases, water vapors can escape through exhaust pipe [9].

8.4 Function
The hydrocarbons (methane, unburnt HCs...) present in exhaust gases strike to the flowing non-
polar liquid solvents (toluene etc.) and absorb/stick with them [10].

The gas SO2 react with calcium carbonate (Desulphurization):

SO2 + CaCO3 → CaSO3 calcium sulfite + CO2

CO2 + H2O ⇌ H2CO3

CO + H2O ⇌ CO2 + H2 mix of CuO, ZnO, Al2O3 [11] [12].

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9 Conclusion
The optimized car exhaust system has low cost of stainless steel and new design will sufficiently
reduce the air pollution due to vehicles.

10 References

[1] https://www.slideshare.net/mayankjaggi1/automobile-exhaust-system-28626560.

[2] https://www.energy.gov/eere/vehicles/articles/internal-combustion-engine-
basics#:~:text=In%20a%20spark%20ignition%20engine,piston%20during%20the%20pow
er%20stroke.

[3] https://en.wikipedia.org/wiki/Density.

[4] https://www.corrosionpedia.com/definition/494/fatigue-strength.

[5] https://en.wikipedia.org/wiki/Thermal_conductivity.

[6] https://rb.gy/ydebyj.

[7] https://rb.gy/cumsqm.

[8] https://rb.gy/frtb4j.

[9] https://rb.gy/d8dit8.

[10] https://rb.gy/wf6y9o.

[11] https://rb.gy/m0krc0.

[12] https://rb.gy/2vlsyx.

[13] https://www.kindpng.com/imgv/iToiToJ_car-exhaust-car-exhaust-png-clipart-transparent-
png/.

[14] https://gomechanic.in/blog/car-exhaust-smoke/.

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[15] https://www.dreamstime.com/photos-images/exhaust-manifold.html.

[16] http://mel0207lsprod.blob.core.windows.net/uploads/global/ls/content/35176/engine/what/
exhaust.html.

[17] https://www.youtube.com/watch?v=W6dIsC_eGBI.

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