M.Ing. / The purpose of this thesis was to gather experimental data of a stainless steel sleeve being formed into a convoluted tube. This convoluted tube, made from stainless steel ASTM 240 type 321 and with a wall thickness of 0,4mm, is the main part of an automotive exhaust bellow. The automotive exhaust bellow fits into a motor vehicle exhaust system. One of the functions of this bellow is to compensate for engine movement. The bellow is also used to damp the engine vibration to the vehicle chassis. Typical failures that occur during the production of a convoluted tube are identified. The data gathered are listed and the forming process, typical conditions and its effects discussed. The actual data and graphs are presented in the annexures at the end of this report. Plasticity theory for shells and cylinders is summarized in Annexure A and the solution of a related problem discussed. Experimental data were used to verify the result of a finite element model. The calculated values of the model compare well with the values of the experimental data. The model must still be developed further and the experimental data can be used to verify this developed model. Possible aspects, related to the forming and life-cycle prediction of an automotive exhaust bellow, that still need to be studied are identified and presented at the end of this report.

Thesis (MScEng)--University of Stellenbosch, 2001. / ENGLISH ABSTRACT: This thesis is concerned with unsteady, one-dimensional flow, which closely mimics those found in the manifolds of internal combustion engines. The physical equations describing problems of this nature are presented and some of the important concepts introduced. These equations and concepts were verified by comparison to published results. The Method of Characteristics (MaC) for unsteady one-dimensional flow with friction and heat transfer was used to analyse the gas flow through the inlet and exhaust systems of an engine. The theoretical derivation of unsteady gas dynamic boundary conditions is presented and the integration with the unsteady pipe flow explained. A simulation flow model was developed to analyse the flow by using the Mae. Thisflow model was then incorporated into an engine simulation program, ESA,to simulate internal combustion engines and to predict the performance of a specific engine. A cam-profile model and an in-cylinder thermodynamic model are used to complete the ESAsoftware. Experimental work was done on a modified Nissan Z24/NA20 engine to evaluate the simulation model. The manifolds of the Nissan Z24/NA20 were modified to isolate one of the cylinders for a proper single cylinder model. More experimental work was done on a Volkswagen 1.6£ 8-valve and a 1.6£ 20-valve engine to obtain performance data on two inlet manifolds developed using the ESAsoftware. Performance data and pressure traces in the inlet manifold of the Nissan Z24/NA20 were recorded for comparison with the ESA software. Good correspondence was found between tested and modelled data and the differences varied between ±5% on engine performance data and pressure wave frequency predictions, and ± 10% on pressure pulse amplitudes. / AFRIKAANSE OPSOMMING: Hierdie tesis handeloor bestendige, eendimensionele vloei, wat die gasvloei in spruitstukke van binnebrandenjins naboots. Die nodige vergelykings wat hierdie tipe probleme beskryf asook van die belangrikste konsepte, word bespreek. Hierdie vergelykings en konsepte is met behulp van gepubliseerde data geverifieer. Die Metode van Karakteristieke (MVK) vir bestendige, eendimensionle vloei met wrywing en warmte oordrag, is gebruik om die gasvloei deur inlaat en uitlaat sisteme van 'n enjin te analiseer. Die teoretiese afleiding van bestendige gasdinamiese randvoorwaardes asook hul integrasie met die bestendige pypvloei, word verduidelik. 'n Simulasie vloeimodel is ontwikkelom die vloei met behulp van die metode van karakteristieke te analiseer. Hierdie vloeimodel is deel van 'n omvattende enjinsimulasie program, ESA. Dit word gebruik om binnebrandenjins te simuleer en enjinwerkverrigting te voorspel. 'n Nokprofielmodel en 'n termodinamiese ontbrandingsmodel word gebruik om die enjinsimulasie program af te rond. Eksperimentele toetse op 'n gemodifiseerde Nissan Z24/NA20 enjin is gebruik om die simulasie model te evalueer. Die spruitstukke van die Nissan Z24/NA20 is aangepas om een van die silinders te isoleer om so 'n geskikte enkelsilindermodel te skep. Verdere eksperimentele toetse is gedoen op Volkswagen 1.6£8- klep en 1.6£ 20-klep enjins. Werkverrigtingsdata is verkry op twee nuwe inlaatspruitstukke wat met behulp van die ESAsagteware ontwerp is. Werkverrigtingsdata en drukverdelingsdata in die inlaatspruitstuk van die Nissan Z24/NA20is aangeteken om te vergelyk met die resultate van die ESAsagteware. Goeie ooreenstemming is verkry tussen toets- en gemoduleerde data. Die verskille varieer tussen ±5% op enjin werkverrigtingsdata en drukpulsfrekwensie voorspellings, en ± 10%op drukpuls-amplitudes.

It is quite common practice in automotive and aircraft engine maintenance, operation, and research to employ any one of several types of instruments now on the market for determining the air-fuel ratio by exhaust gas analysis. It was the purpose of this investigation to determine the most important operating characteristics, especially range and accuracy, of each of these types of instruments. The theory underlying the operation of this kind of apparatus was studied critically, and certain tests were performed on representative makes in order to observe the operation of each type under service conditions. These tests consisted essentially of connecting the analyzers to the exhaust pipe of a single-cylinder engine and comparing the analyazer readings with the true air-fuel ratio determined by accurately measuring the air and fuel supplied to the engine while the instruments were being observed. This procedure was repeated for a number of different carburetor settings, all other factors being kept as nearly constant as possible during a given series of runs. The effect of variations in engine spark advance and the pressure of the gas supplied to the instruments was also investigated. The test revealed several interesting facts. Study of the operating principles of the several instruments indicated that they were limited te air fue1 ratios below about 14 to 1, and this has been conclusively proved by these experiments. This limitation applies to thermal conductivity, hot-wire catalytic, and relative density types. W While the most expensive makes of instruments were not tested, it was found that, in general, the limit of accuracy is not greater than one-half of one air-fue1 ratio, regardless of the operating principle employed. Large variations in the pressure and rate of flow of the exhaust supplied to the analyzers were found to cause considerable deviations in those instruments which did not employ some kind of device to insure a steady and uniform supply. Certain features of design and construction which effect the reliability of the various types of exhaust gas analyzers are also reviewed in this thesis, and some of the more important chemical methods of analysis are treated briefly. / Master of Science