BFF-2423 - Manufacturing Processes - Project Report - Engineering Assignment Help

Assignment Task

Introduction

Exhaust manifold plays the leading role in a vehicle’s exhaust system. The exhaust manifold can be considered as the ‘lungs’ of an engine as it covers various functional processes in an automobile. This exhaust manifold connects to each exhaust port on the engine's head, collects the exhaust gases from multiple cylinders and deliver it into an exhaust pipe. It exhales the gases which generated during the combustion process and sends the gases out through the pipe to make way for fresh oxygen in each cylinder.

In developing an exhaust manifold, the use of materials with high resistance to heat property is relatively necessary in order to prevent thermal corrosion from limiting the service life of the exhaust as it is always exposed to hot gases. Material selection for the exhaust system is very important because of the increased warranty requirements and regulatory compliances in automotive industry nowadays. The materials characteristics used for manufacturing of exhaust system should has high service temperature, high fatigue strength, high fracture toughness, easily machinable and economic by considering the overall cost of the automobile. In such a period of time, the most common types of exhaust manifold in the market are made of mild steel. However, over the years, stainless steel and cast iron has replaced mild steel in exhaust systems as the mild steel has very poor corrosion resistance to withstand exhaust temperature and not meet the demand in power and environmental safety. Cast iron manifolds can be manufactured by the sand-casting process. Development of the exhaust manifold required equal length of pipes and good exhaust gas flow. Failure in that system can cause loss of back pressure which affect engine performance parameters.

Objective

i. To design and manufacture exhaust manifold

ii. To identify the processed needed in making the exhaust manifold

iii. To determine the total cost in making exhaust manifold by using appropriate processed.

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