Numerical Flat Silencer Shape Optimization

Flat muffler geometries are increasingly used in hybrid vehicle concepts. The investigated design features an elliptical mantle with press-formed baffles, held in place solely by friction forces. A key challenge is the proper sizing of the baffles to ensure sufficient normal forces are maintained even under operating conditions. Incorrect sizing may lead to deformation, insertion failures, or inadequate positioning. A thermomechanical finite element simulation is used to analyze the insertion process at room temperature and the heating under operating conditions. Based on this, the baffle shape is optimized with regard to contact behavior. A mathematical model predicts the contact behavior based on geometric parameters. The results allow for a transferable design approach for similar geometries without the need for time-consuming mechanical simulations.