Thermo-elastic stress assessment of exhaust manifold outlet dimensional deviations in a heavy-duty diesel engine

Parhizkar Yaghoobi, Mohammad; Rajabi, Emad

doi:10.22068/ase.2026.732

Volume 16, Issue 1 (3-2026) ASE 2026, 16(1): 4953-4965 | Back to browse issues page

‎ 10.22068/ase.2026.732

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Parhizkar Yaghoobi M, Rajabi E. Thermo-elastic stress assessment of exhaust manifold outlet dimensional deviations in a heavy-duty diesel engine. ASE 2026; 16 (1) :4953-4965
URL: http://ase.iust.ac.ir/article-1-732-en.html

Thermo-elastic stress assessment of exhaust manifold outlet dimensional deviations in a heavy-duty diesel engine

Mohammad Parhizkar Yaghoobi

, Emad Rajabi

MAPNA Turbine Engineering and Manufacturing Company (TUGA)

Abstract: (283 Views)

Generally, parts whose geometric form in the final configuration, or before additional operations such as machining, does not require special dimensional accuracy are produced using casting methods. Producing parts with this method results in significant deviations in dimensions and geometric forms from the main designed geometric model. Due to economic considerations, scrapping such parts will result in energy and material waste and high costs. In this study, dimensional deviations at the exhaust manifold outlet and deviations from the defined geometric tolerance limits of the part during the repair process are identified as geometric non-conformities and investigated using computer tools. Considering the harsh operating conditions under which the engine is under full load, the temperature distribution is determined using computational fluid dynamics, and the thermo-elastic stress distribution is calculated using the finite element method, accounting for the loads applied to the structure. The main part model and the non-conforming models with upper and lower limits in geometric dimensions have been investigated with respect to the deviation in thermo-elastic stress relative to the reference value in the part with the nominal size. The results showed that, given the amount of stress changes in the desired area of parts with deviations from the main design, these parts are also usable and have a lifetime almost the same as a part produced with the nominal size.

Keywords: Exhaust Manifold, Heavy-duty Diesel Engine, Thermo-Elastic Stress, Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA)

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Type of Study: Research | Subject: Manufacturing