Weldless Flange Connections

Abstract: This development project is a bachelor’s degree thesis work that will conclude the education program ”Development Technology” at Blekinge Institute of Technology. The development project has been done in cooperation with Faurecia Exhaust Systems AB in Torsås that constructs and manufactures manifolds, catalytic converters, mufflers and whole exhaust systems. The task with this project was to find a new solution concept for the connection of pipes into flanges in manifolds. The concept that Faurecia uses today for their manifolds is based on welding the pipes into place in the flange. The product development model that is used in this project is written by Fredy Olsson. For this project have the parts ”Principal construction” and ”Primary construction” been used. During the principal construction has a product definition been made and the criterions that should be satisfied by the following solution concept was determined. Several solutions were designed and evaluated by the project members and in cooperation with the supervisors at Faurecia. The solutions that were subject for further development were prepared during the primary construction with for example CAD. Three solution concepts were the result from this thesis work. All of the solution concepts contain end shaped pipes that provides the sealing area against the engine. The main difference between them is that the flange is designed in different ways.