Numerical simulation and design of casting system for stainless steel exhaust manifold

¹ Department of Mechanical Engineering, National Pingtung University of Science and Technology, Pingtung 912, Taiwan
² Department of Greenergy, National University of Tainan, Tainan 70005, Taiwan
³ Department of Mechanical Engineering, National Kaohsiung University of Applied Sciences, Kaohsiung 807, Taiwan

^* Corresponding author: phhuang1970@gmail.com

Abstract

During operation, exhaust manifolds must bear the corrosion of high temperatures and repeated stress, which can easily lead to cavitation, corrosion, and creeping damage in the casting structure and affect product safety. To improve the structure of exhaust manifolds and increase their service life, we employed AnyCasting mold flow analysis to SUS304 stainless steel exhaust manifolds. We examined the influence of casting system design and process parameters such as ceramic shell temperature, casting temperature, and pouring speed on the filling and solidification processes of the liquid metal. Finally, we used the Niyama criterion to predict the probability and distribution of shrinkage porosity defects in the exhaust manifold and made improvements to enhance the quality of exhaust manifold castings. Keywords: exhaust manifold, mold flow analysis, casting system.