FEA Simulation and Experimental Validation of Catalytic Converter Structural Integrity

Paper #:
  • 2000-01-0219

Published:
  • 2000-03-06
Citation:
Taylor, W., Fuehne, J., Lyon, R., Kim, J. et al., "FEA Simulation and Experimental Validation of Catalytic Converter Structural Integrity," SAE Technical Paper 2000-01-0219, 2000, https://doi.org/10.4271/2000-01-0219.
Pages:
12
Abstract:
Non-linear FEA models are applied to three different catalytic converters, with the objective of predicting structural parameters such as shell deformation, push-out force, and mounting-system contact pressure under various conditions. The FEA modeling technique uses a novel constitutive model of the intumescent mat material typically found in ceramic-monolith converter designs. The mat constitutive model accounts for reversible and irreversible thermal expansion, allowing for the prediction of the one-way converter deflection observed in hot durability tests. In addition to this mat material model, the FEA methodology accounts for elastic and plastic shell deformation, contact between materials, and a three-dimensional temperature field in the shell and mat. For each of three designs, predictions are presented for converter canning, heat-up, and cool-down (i.e., post-heating) conditions. Measured push-out force and shell deflections are presented alongside the FEA predictions, with good agreement between experimental and computed trends.
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