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 Mission
The mission of the R & D is to provide full exhaust system
development support to OEMs and engine manufacturers. Power
train
understanding, exhaust system component identification, material
selection, and system layout are performed using in-house
developed design tools. Computational fluid dynamics (CFD),
finite element analysis (FEA) and engine simulation modeling
(WAVE) are used to design, optimize and validate exhaust system.
On-road, off-road, and non-road vehicle exhaust system will be
developed and validated for global OEMs and engine
manufacturers. This pro-active development methodology will
provide comparative and competitive advantage to OEMs. Emission
control systems such as Three Way Catalyst (TWC), Diesel
Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), Lean
NOx Trap (LNT), Selective Catalytic Reduction of NOx (SCR) and
Hydro Carbon Trap (HC trap) are being developed. Modular exhaust
system development includes tailpipe noise reduction and
acoustic optimization.
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Understand Emissions Requirement and Customer Targets
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Lead Advanced Emission Control Technologies
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Establish Exhaust Product Design, Development, Validation
and Manufacturing
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Manage Extended Enterprises to Keep up with Product
Innovations
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Provide Customer Support for Exhaust Product Development
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Involve Modeling and Simulation Tools to Design and Optimize
Exhaust Components and Full System
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Plan and Execute Joint Development and Partnership Program
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Design Process |
Application |
Software capability |
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Power train understanding
and exhaust system layout |
Identification of
components and materials. Determining layout
(location, geometry and orientation) |
1D Exhaust System
Design Models (in house |
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CAD |
System design/ 3D
parametric modeling |
Catia V5, AutoCAD,
Unigraphics |
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Fluid dynamics |
Flow optimization/
Thermal Management/ Chemical reaction/ pressure
drop |
STAR CD, Star CCM+ with
chemical model, DARS |
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Structural |
Thermal, engine and road
load Stress analysis/ NVH/ Fatigue/ Manufacturing
tolerance |
MSC Nastran, MSC Patran |
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Radioss. Hypermesh,
Hyperview |
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System simulation and
gas dynamics |
Engine simulation and
system performance (BP, TL etc) |
WAVE |
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Manufacturing |
Optimization of
manufacturing process tolerances |
Monte – Carlo
Simulation
(in house) |
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Exhaust
System Development |
Product
Development Focus |
Catalytic
converter Design |
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Material Choice |
Design |
Development |
Packaging |
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Substrate Choice |
Catalyst Sizing |
Catalyst Loading |
Material Selection |
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Ceramic |
D/l optimization |
Chemical CFD |
Durability |
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Metallic |
Cell Size and Count |
PGM loading Stabilizer |
Passivity |
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Size |
Catalyst Size |
Basemetal loading |
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Surface Area |
Flow Distribution |
Washcoat Loading |
Alignment Integrity |
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Back Pressure |
Material |
Site Compatibility |
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Washcoat/Catalyst |
Space velocity distribution |
Thickness |
Alignment in Vehicle |
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Quantity |
Effect of Plug |
Stability |
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S.A./Pore Size |
Production Inhibition |
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Active/Passive |
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Mat Selection |
Components/Canning |
Microstructure Analysis |
NVH Considerations |
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Mat Thickness |
Manifold Design |
Fresh sample |
Hanger design/placement |
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Thermal Expansion |
Down pipe design |
Aged sample |
Insulator design/placement |
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Binder Evaporation |
Inlet/Outlet core design |
Field return sample |
Flex coupling design |
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Thermal Stability |
Shell design |
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Heat shield design |
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Canning |
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Heat Management |
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Clam Shell |
Duel wall pipes |
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Stuffing |
Sheet Metal manifold |
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Tourniquet |
Insulation Cones |
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Performance Test |
Durability Test |
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Catalyst Efficiency |
Mechanical Design |
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Engine data |
Strength |
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Performance |
Elastic Properties |
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Aging effect |
Engine vibration |
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Stability |
Road Impact |
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Fatigue |
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Road Test |
Thermal Durability |
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User results |
Temperature gradients |
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Customer data visit |
Thermal expansion |
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Problem analysis |
Heat transfer |
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Improvement |
Substrate Deterioration |
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Catalyst sintering |
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Converter Aging |
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Catalyst masking |
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Irreversible change |
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Microstructural change |
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Sintering |
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Converter Shell Deformation test |
Full Exhaust System Testing |
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Thermal Profile Test |
NVH Testing |
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Ambient and Hot Vibration Test |
Fatigue Salt Spray Test |
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Hot/cold Push test |
Metallurgy, Metrology and Metallographic Lab |
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Flow Lab |
Machine shop |
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Compression Test ( Instron 5900 Model) |
Wet Chemistry Lab |
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