Thermal external cracks can be initiated at the parting line, which is the dividing line that splits the core and cavity halves of a molded exhaust manifold-turbine housing. The fatigue cracks are often resulted from hot-cold cycle loads called by thermal shock cycles, and are accompanied by large plastic strains. This paper investigated the effects of parting lines of the integrated exhaust manifold-turbine housing and compared the magnitude of plastic strains directly correlated to low cycle fatigue damages or cracks. The finite element results showed that the plastic strains at runner junctions including parting line was calculated by 0.68%, which is approximately 60% higher than that of the turbine housing considering no parting line. So, if the analysis target is less than 0.50 % of plastic strain amplitude, the fatigue damages or cracks could be expected by considering the parting lines in integrated exhaust manifold-turbocharger.

This paper presents a method for the assesment of vibration fatigues in engine exhaust system. Analysis technologies by virtual model can reduce the number of physical tests and development cycles. The prediction processes are based on the construction of FE model for the exhaust system, normal mode analysis, and frequency response analysis. The analysis results(1st mode: 152Hz) of eigen frequencies are compared with the modal test results(1st mode: 151Hz). And frequency response analysis for accelerations and stresses at critical locations were also presented. The analysis method could be applied to assess the vibration fatigue for the engine exhaust manifold. As a result, maximum stress occurred at the end of diffuser and its frequency shows around 1st natural frequency of exhaust system. It shows a good agreement between numerical and experimental results.