Development of affordable high-performing passive exhaust systems and manufacturing technology

Exhaust systems for military vehicles have a significant impact on automotive performance and acoustic signatures. Due to the variety of performance specifications and military standards for noise requirements, extensive silencer design work and analysis is required for each new system. Much time is spent iterating between analysis models to achieve the desired attenuation and flow performance. The relatively low volumes of new exhaust systems needed for military applications presents a manufacturing challenge as well. In many cases exhaust systems must be designed to fit into very restricted space claims. This drives the need for complex shapes and configurations of muffler elements requiring costly, labor intensive manufacturing processes and long lead times. It is a unique challenge to make these exhaust systems more affordable while maintaining engine power and meeting noise requirements. Specific technical activities include definition of a modular design space, development of a software based expert design optimization system including automated manufacturing plan generation, and development of manufacturing technology to support semi-automated manufacturing of the passive high performing exhaust system.