Integration of TWC & GPF into exhaust system & validating durability (vibration & thermo- mechanical effect) through virtual analysis & prototype to make system for EURO 6-c norms

The aim of the paper was to enhance the existing cold end exhaust system by integrating a Gasoline Particulate Filter (GPF) system to eliminate particulate matter generated during combustion, ensuring compliance with Euro 6.2c emission standards. The current cold end underfloor with Three-Way Catalyst (TWC) lacked a GPF, resulting in non-compliance with Euro 6.2c emission regulations. It focuses on optimizing the inlet cone of a catalytic converter to achieve specific flow-related goals, ensuring the efficient utilization of the entire catalytic converter monolith. A higher uniformity index is crucial for enhancing the catalytic converter's efficiency. Subsequently, the baseline design of the catalytic assembly is examined, and modifications are applied to the inlet cone design. Additionally, Utilizing Computer-Aided Engineering (CAE) tools to evaluate durability against vibration, thermomechanical effects, and other system properties, designs generated in CATIA software were analyzed and optimized. Subsequently, prototype samples were produced in-house, with SN testing conducted on the UFC inlet section to evaluate joint capacity, comparing it with safety factors. Furthermore, thermal fatigue tests were carried out on the samples to assess system sag resulting from thermal cycling and failure due to thermally induced stress. The observed sag was within the customer's specified limits, and the leak rate remained within regulatory bounds. The CAE tool results showed significant correlation with experimental and prototype findings, indicating no need for modifications based on physical testing results.