Design and Optimization of an Exhaustive Muffler and Experimentation to reduce Emission using Fly ash

Abstract

Exhaust gases from the combustion of the air-fuel mixture are reduced to non-harmful gases before releasing them into the atmosphere using a catalytic converter. Exhaust muffler or silencer are used to reduce noise and vibrations level due to the expansion of gases. In this research, a novel muffler is designed for 4-stroke, 125cc single-cylinder petrol engine and structural analysis are carried out for optimization using ANSYS Static Structural solver. The muffler is subjected to various pressure loads, acceleration loads, and load due to self-weight. Fatigue analysis is further carried out using stress-life approach and mean Soderberg theory of failures to determine Life, Damage, Safety factor, Biaxiality Indication, and Alternating equivalent stress under dynamic loading. Experimental analysis is carried out using an optimized muffler with fly ash as a catalyst to determine the reduction in emission. Structural analysis of the initial model was optimized by slight modification in design which reduced total deformation from 0.0379 mm to 0.0374 mm and equivalent stress from 52.878 Mpa to 50.969 Mpa. The safety factor was also increased from 1.6302 to 1.6902. Experimental results using Gas analyzer used for emission readings have shown a reduction in the emission of carbon monoxide and hydrocarbons by 21.06% and 23.07% respectively as compared to a standard muffler.