DEPARTMENT OF MECHANICAL ENGINEERING

VASIREDDY VENKATADRI INSTITUTE OF TECHNOLOGY: : NAMBUR

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA

CERTIFICATE

This is to certify that the project entitled “DESIGN AND FABRICATION OF

AQUA SILENCER” is a bonafide record of work done by Mr.BAJI ALI BAIG,
Mr.G.KOUNDINYA, and Mr.D.HARI BABU, Mr.K.ASHOK Regd.No. 15BQ5A0302,
14BQ1A0332, 14BQ1A0324 and 15BQ5A0308 respectively, under the guidance of
P. Nageswara Rao, Associate Professor in partial fulfilment of the requirement for
bachelor of technology in Mechanical Engineering, JNTUK during the academic
year 2017-18.

P. Nageswara Rao Dr.K.SATYANARAYANA

Project Guide Head of the Department

1
 DECLARATION

We, BAJI ALI BAIG (15BQ5A0302),G.KOUNDINYA

(14BQ1A0332),D.HARI BABU(14BQ1A0324),K.ASHOK (15BQ5A0308) hereby
declare that the Project Report entitled “DESIGN AND FABRICATION OF AQUA
SILENCER” done by us under the guidance of P.NAGESWARA RAO, Assos.
Professor, Dept. of ME is submitted in partial fulfilment of the requirements for the
award of degree of BACHELOR OF TECHNOLOGY in MECHANICAL
ENGINEERING

DATE :

PLACE : Nambur

SIGNATURE OF THE CANDIDATES

BAJI ALI BAIG

G.KOUNDINYA

D.HARI BABU

K.ASHOK

2
 ACKNOWLEDGEMENT

We express our sincere thanks wherever it is due

We express our sincere thanks to the Chairman, Vasireddy Venkatadri

Institute of Technology, Sri Vasireddy Vidya Sagar for providing us well equipped
infrastructure and environment.

We express our sincere thanks to our beloved Director Dr. Naveen Ravela
for providing support and stimulating environment for developing the project.

We thank Dr. Y. Mallikarjuna Reddy, Principal, Vasireddy Venkatadri Institute

of Technology, Nambur, for providing us the resources for carrying out the project.

Our sincere thanks to Dr. K. Satyanarana, Professor and Head, Dept. of ME

for his co-operation and guidance in helping us to make our project successful and
complete in all aspects.

We also express our sincere thanks and are grateful to our guide
P.Nageswara Rao, Assoc. Professor, Dept of ME, for motivating us to make our
project successful and fully complete. We are grateful for his precious guidance and
suggestions.

We also place our floral gratitude to all other teaching staff and lab
technicians for their constant support and advice throughout the project.

NAME OF THE CANDIDATES

BAJI ALI BAIG

(15BQ5A0302)
G.KOUNDINYA
(14BQ1A0332)
D.HARI BABU
(14BQ1A0324)
K.ASHOK
(15BQ5A0308)

3
 ABSTRACT

An Aqua Silencer is mainly dealing with control of emission and noise in

automobile exhaust. By using activated charcoal, perforated tube and outer shell it

is constructed. An aqua silencer is fitted to the exhaust pipe of engine. The activated

charcoal filters the harmful sulphur and nitrous content produced from the engine.

Sound produced under water is less hearable than it produced in atmosphere. This

mainly because of small sprockets in water molecules, which lowers its amplitude

thus, lowers the sound level. Because of this property water is used in this silencer

and hence its name AQUA SILENCER. It is tested in single cylinder 4- stroke petrol

engine and the noise and smoke level is considerable less than the conventional

silencer. The main pollutants contribute by automobiles are CO, UBHC, Nox and

Lead etc., other sources such as electric power generating stations, industrial and

domestic fuel consumption, refuse burning, industrial processing. So it is imperative

that serious attempts should be made to conserve earth’s environment from

degradation. An aqua silencer is an attempt in this direction; it is mainly dealing with

control of emission and noise.

4
 LIST OF FIGURES

S.No Name Page Number

1 Concept Development 15

2 Reactive Silencer 16

3 Absorptive Silencer 17

4 Combination Silencer 18

5 Spark Arresting Silencer 19

7 Working of Aqua Silencer 25

8 Block Diagram of Aqua Silencer 26

9 Charcoal Layer 35

10 Lime Powder 38

11 Perforated Tube 36

12 Non Return Valve 39

13 H-Nipple 39

5
 LIST OF TABLES

S. No Name Page No

1 Raw Material and Standard Material 45

2 Raw Material and Standard Material Costs 47

6
 CONTENTS

Chapter NO CHAPTER PAGE

ABSTRACT i

LIST OF FIGURES ii

LIST OF TABLES iii

1 INTRODUCTION 1-24

1.1 History 1-12

1.2 Need of Project 13
1.3 Product Development 14
1.4 Types of Silencer 15-24

2 PRINCIPLE AND BLOCK DIAGRAM 24-16

2.1 Principle 25
2.2 Block Diagram 26

4 METHODOLOGY 42

6 LIST OF EQUIPMENT AND COST ESTIMATION 43-47

6.1 List of Equipment 43

6.2 Cost Estimation 47

7 RESULTS AND DISCUSSION 49

8 PHOTOGRAPHY 51-52

8 FUTURE SCOPE 54

7
9 CONCLUSION 55

10 BIBILOGRAPHY 56

8
 INTRODUCTION

Silencer is also termed as muffler. It is used for reducing the noise emitted

by exhaust of an internal combustion engine, which is a major source of noise

pollution. It becomes a more vital concern when used in residential areas or areas

where noise creates hazard. Generally, noise level of more than 80-90 dB is

injurious for human being. The main source of noise in an engine are divided in two

parts, first is the exhaust noise and second is the noise produced due to friction of

various parts of the engine. The engine exhaust noise is the most dominant. To

reduce this noise, the most effective way of using a muffler in the engines. The level

of noise reduction depends upon the design, construction and the working

procedure of mufflers. If a car running without a muffler then the noise level is

unbearable. The most of the advances in the acoustic filters and exhaust mufflers

came out in last four decades. Hence good design of the muffler should give the

best noise reduction and offer optimum backpressure for the engine. Backpressure

is the extra static pressure exerted by muffler on the engine through the restriction

in the flow of exhaust gases. The insertion loss is defined as the difference in the

acoustic power radiated without and with the muffler fitted.

EXHAUST SILENCER

Engine exhaust noise is controlled through the use of silencers and

mufflers. Generally speaking, there is no technical distinction between a

silencer and muffler and the terms are frequently used interchangeably. A
9
silencer has been the traditional name for noise attenuation devices, while a

muffler is smaller, mass-produced device designed to reduce engine exhaust

noise.

SILENCER SELECTION FACTORS

The use of an exhaust silencer is prompted by the need to reduce the engine

exhaust noise. In most applications the final selection of an exhaust silencer is

based on a compromise between the predicted acoustical, aerodynamic,

mechanical and structural performance in conjunction with the cost of the resulting

system.

ACOUSTICAL PERFORMANCE

The acoustical performance criterion specifies the minimum insertion loss

(IL) of the silencer, and is usually presented in IL values for each octave band as

well as an overall expected noise reduction value. Octave bands and sound

attenuation are discussed in further detail in Chapter 25. The insertion loss is

determined from the free-field sound pressure levels measured at the same

relative locations with respect to the outlet of the unsilenced and silenced

systems. The IL of a silencer is essentially determined by measuring the noise

levels of a piping systems before and after the insertion of a silencer in the

exhaust stream. IL data presented by most manufacturers will typically be based

upon insertion of the silencer into a standard piping system consisting of specified

straight runs of piping before and after the silencer. Exhaust system

configurations as well as mechanical design can have a substantial Impact on the

performance of and exhaust silencer and should be considered at the time of

specification. Raw exhaust noise levels should be obtained from the engine

10
manufacturer to determine the necessary noise reduction requirements of the

proposed silencer. Specific installation conditions and exhaust noise levels will

aid the manufacturer in determining the correct silencer to meet the required

noise reduction.

If a silencer is located outside of the room or housing in which the engine is

installed, one must be cognoscente of the effects of ‘break-out’ noise from either

the silencer body or associated piping system. Breakout noise can dominate the

stack radiated noise, particularly for high performance silencers that greatly

reduce the noise transmitted downstream. A high performance exhaust silencer

may have extremely good IL performance, but utilization of a thin walled piping

system may allow substantial noise to be radiated from the piping system before

entering the silencer body. The effects of sound transmission through a mass

layer are discussed in Chapter 25. One solution avoids potential breakout from

dominating the overall noise levels is to ensure a balance between the exhaust

silencer shell thickness and corresponding piping. Manufacturers will often

incorporate a multiple layer shell on higher-grade silencers to increase the

transverse transmission loss of the silencer.

AERODYNAMIC PERFORMANCE

The Aerodynamic performance criterion specifies the maximum

acceptable pressure drop through the silencer (backpressure of the

silencer). The exhaust flow rate and temperature from the engine

manufacturer are required to accurately predict the backpressure of a

silencer and piping system. Selection of an exhaust silencer based solely on

the diameter of the connecting piping can often lead to improperly selected

11
products that may present installation issues. Traditional head loss

calculations utilizing standardized coefficients for sudden contraction and

expansion of fluids can be used to approximate the pressure drop through a

silencer and combined with the values obtained for the remainder of the

piping system. More complex silencer internal structures should be analysed

using Computational Fluid Dynamics (CFD) where traditional empirical

calculations or assumptions may lead to inaccurate results. The pressure

drop through silencers should be obtained from the manufacturer of the

product upon submission of the required flow information.

MECHANICAL PERFORMANCE

The Mechanical performance criterion specifies the material properties of

the exhaust system to ensure that it is durable and requires little maintenance

when incorporated into service. Material selection is especially important in cases

involving high temperature or corrosive gases. Traditional carbon steels will

typically be sufficient for the majority of applications using Diesel fuelled

generators. Natural Gas engines will traditionally run at an elevated temperature

above their Diesel counterpart, and may require a graded carbon or stainless

steel that can maintain an element of structural performance at elevated

temperatures. Aluminized steel is available from many silencer manufacturers

and is often preferred for general applications. Aluminized steel is slightly more

heat resistant than carbon steel and offers an increased resiliency to corrosion

and is often selected as an economical alternative to specifying a stainless steel

system. Regular periodic testing of a standby generator will subject the exhaust

system to thermal cycles that can contribute to the premature corrosion of carbon

steel.
12
STRUCTURAL PERFORMANCE

The Structural performance criterion can specify the geometric restrictions

and/or maximum allowable volume/weight of the silencer that can substantially

influence the silencer design process. Secondary loading outside of the weight of

the silencer can also affect the design and cost of the exhaust system. A standard

engine silencer is not traditionally designed to absorb substantial loads due seismic

activity, wind or thermal growth of adjacent piping. Silencers that are specifically

incorporated as an element of an exhaust “stack” should be designed to

accommodate the loads that will be absorbed due to potentially high wind loads as

well as seismic activity. A commodity purchased silencer should be isolated from

substantial piping runs through the use of flexible expansion joints to reduce or

eliminate the transfer of loads and engine vibration. Customized silencers can

easily be designed when the force and moment values that can be placed on a

connection are indicated at the time of quotation.

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 NEED OF PROJECT

 . To reduce harmful gases from vehicle exhaust system such as carbon

monoxide (CO), unburnt hydrocarbons (UBHC), oxides of nitrogen (NOx) &

lead (P b) getting mixed with environment.

 To reduce overall temperature of exhaust gases coming out of vehicle

exhaust system & thereby reducing the emission of greenhouse gases

adding to the global warming.

 To reduce undesirable noise at tail pipe of exhaust system of a vehicle& help

to reduce level of noise pollution.

 To select easily available material for outer shell as a resource, so that it can

be easily fabricated at a minimum possible cost.

 To design such a model that can be an alternative for conventional catalytic

converter, at minimum possible cost.

 To fabricate a designated model in such a way that activated charcoal &

water used are easily replaceable& also water from shell won’t get mixed

with exhaust manifold.

14
 CONCEPT DEVELOPMENT

Glass Wool Felt filter

Filter

Charcoal Exhaust Inlet

Layer

Engine
Water

Scrubber

Perforated
Tube

Drain Out

15
 TYPES OF SILENCERS

Despite the terms and myriad of configurations, the silencer can be broken

into three fundamental types: reactive (reflective), absorptive (dissipative), and

combination reactive/absorptive. In addition to the three main silencer types, other

functionality such as spark arresting, emission control, heat recovery, etc., may

also be incorporated into the silencer design. Each type of silencer has specific

performance attributes that can be used independently or in combination to

produce the required IL for a specific application. A number of additional silencer

styles and options are also reviewed in the following sections.

Reactive silencer

Reactive silencers generally consist of several pipe segments that

interconnect with a number of larger chambers. The noise reduction

mechanism of reactive silencer is that the area discontinuity provides an

impedance mismatch for the sound wave traveling along the pipe. This

impedance mismatch results in a reflection of part of the sound wave back

toward the source or back and forth among the chambers. The reflective

effect of the silencer chambers and piping (typically referred to as

resonators) essentially prevents some sound wave elements from being

transmitted past the silencer. The reactive silencers are more effective at

lower frequencies than at high frequencies, and are most widely used to

attenuate the exhaust noise of internal combustion engines. A generic

16
reactive engine silencer comprised of two proportionally sized chambers with

a pair of interconnecting tubes is shown below.

Figure 1 Reactive Silencer

Absorptive silencer

Absorptive silencers contain fibrous or porous sound-absorbing materials

and attenuate noise by converting the sound energy propagating in the

passages into heat caused by friction in the voids between the oscillating

gas particles and the fibrous or porous sound-absorbing material. The

absorptive characteristics of materials are discussed in further detail in

Chapter 25. Absorptive silencers usually have relatively wideband noise

reduction characteristics at middle and higher frequencies. Absorptive

silencers are often used to attenuate the engine intake noise or supplement

the performance of reactive silencers for the engine exhaust noise control.
17
The sound absorbing materials are generally held in position by the use of a

perforated metal liner. Knowledge of the structural content of an exhaust

system is important when considering the inclusion of a catalytic element or

Selective Catalytic Reduction (SCR) system in conjunction with the silencer.

Particulate migration of the insulation into the exhaust stream over a period

of time can cause the catalytic element to become fouled and substantially

impact or impede its performance.

Figure 2 Absorptive Silencer

Combination silencer

Some silencers combine both reactive and absorptive elements to extend the

noise attenuation performance over a broader noise spectrum. Combination

silencers are also widely used to reduce engine exhaust noise. Figure 19-1 shows

18
typical noise attenuation curves of reactive, absorptive, and combination silencers.

Figure 3 Combination Silencer

Spark arresting silencer

Federal, state, local and municipal bylaws often dictating exhaust installations

have provisions for arresting sparks from internal combustion engines. If an engine

is to be used in an area where there is potentially dry vegetation of other

combustible materials that are likely to be ignited by any hot carbon passing

through the exhaust, one must incorporate spark-arresting capabilities into the

silencer. Most approved spark arresting systems will employ diffusers or modified

interconnecting tubes that create a centrifugal flow action in the exhaust to direct

carbon particulate into a collection chamber. The particulate trap should be

periodically inspected and cleaned to ensure proper functionality of the spark

arresting capabilities of the silencer.

19
Figure 4 Spark Arresting Silencer

Catalytic silencer

To enhance exhaust gas emission control one may incorporate a catalytic

converter element into a silencer to reduce the Oxides of Nitrogen (NOx), Carbon

Monoxide (CO), and Non-Methane Hydrocarbons (NMHC) discharged in the

exhaust stream. A catalytic converter is comprised of a Knox catalyst and an

oxidation catalyst. The Knox beds reduce the Knox into benign N2 and H2O,

while the oxidation catalyst reacts with CO and HC to form water vapour and

carbon dioxide. Inclusion of the catalytic element into the body of an exhaust

silencer can reduce the cost of a combination system by eliminating the need for

a separate acoustic silencer as well as a specialized catalyst housing and

tracking system.

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Heat recovery silencer

Most of the energy available in the fuel used in reciprocating and gas turbine

engines is rejected in the form of heat. A reciprocating engine running at full load

converts about one-third of the available energy into useful work, while the

remaining two thirds of the available energy is lost in the form of heat rejection. In

a prime power installation where the rejected heat can be used to provide energy

to auxiliary applications a heat recovery silencer can yield attractive savings.

Typical applications of heat recovery silencers for internal combustion engines

include hot water heating, steam generation, heat transfer fluid heating, etc.

Tuned silencer

When the low frequency noise within a narrow band is extremely high, a

tuned silencer can be designed to combat the specific offending frequencies. Tuned

silencers consist of pipe segments and cavities that are used to produce a low

frequency resonance at a required frequency. The accurate prediction of the tuned

(resonance) frequency is extremely important to facilitate a match of the peak

frequency for reducing the narrow band noise to a desirable level. A small deviation

of the silencer resonance frequency from the peak frequency of the noise will

greatly degrade the silencing ability.

21
Active silencer

Active silencing, or sound cancellation systems, employ detectors used in

sensing the noise in an exhaust pipe and a loudspeaker that is used to reintroduce

an inverted signal have been developed to reduce low frequency noise. The

theoretical effect of reintroducing an inverted signal will result in complete

elimination of sound from the exhaust silencer. Although the idea of sound

cancellation is very simple and attractive, there are a variety of complications and

problems arising from erratic fluctuations in the sound source. Active silencing is

relatively expensive at the present time, and its acoustic attenuation performance

at high frequencies is also limited. Widespread use will be dependent upon

continued development of lower cost systems with improved performance realized

through the use of better analytical algorithms, transducers and processors.

System arrangement

A generic exhaust system collects hot exhaust gases from the engine and

discharges them to the environment as quietly and efficiently as possible. An

exhaust arrangement with minimized backpressure and satisfactory noise

attenuation characteristics will usually be the result of a well-specified system. The

exhaust termination points should not be in close proximity to the air intake system

for the engine or the ventilation system of adjacent structures and should comply

with all federal, state, and local regulations. Physical characteristics of the

equipment room can also determine the specific configuration of an exhaust system

layout and should be considered at the conceptual layout phase of the design.

22
Exhaust silencer

The most widely used structural shapes of silencers are the cylindrical

configurations with end-inlet/end-outlet, side-inlet/end-outlet, and side-inlet/side-

outlet. When a silencer is installed on top or inside of enclosure, the side-

inlet/end-outlet configuration is most popular. This enables a minimum of piping.

Hockey puck and rectangular shape silencers are used sometimes due to space

limit. Silencers require traps to drain moisture. Traps installed at the lowest point

of the silencer prevent rainwater from reaching the engine.

Exhaust Accessories

Most exhaust systems will be comprised of flexible connectors, connecting

piping, an exhaust silencer, stack and rain caps. All exhaust systems must be

isolated from the engine with flexible connections to reduce or eliminate the

possibility of structural damage caused by cyclic vibration. A flexible connection

is also used to isolate the weight of the exhaust system from the engine to allow

relative shifting of exhaust components due to thermal growth. Thermal growth of

exhaust piping must be anticipated and supporting members as well as fixed

points should be placed to avoid excessive load on supporting structures and

minimize transverse loading on the flex connector. The exhaust system shown in

Figure 19-2 is referred to as a dual system that uses separate silencers and flow

paths for each engine outlet. A flexible Y Connector may also be used to merge

the exhaust gases from a dual outlet engine into a single inlet silencer where

space permits. Mounting bands and supports should be designed to withstand all

seismic, thermal and dead loads at the elevated temperatures that will be

23
encountered during service. A wall or roof insulating thimble is generally required

when the exhaust system passes through a combustible wall or roof and should

be compliant with all applicable federal, state, and local fire codes. Rain caps are

traditionally used to prevent precipitation from entering the exhaust system when

the generator is idle.

Thermal insulation

Thermal insulation blankets may be needed to wrap the exhaust system to

prevent excessive heat radiation into the generator room or to protect service

personnel from exposure to extremely hot piping components. Flexible pipe

connections, when insulated, must expand and contract freely within the insulation.

The majority of insulation products traditionally used in engine exhaust systems

consist of either an aluminium wrapped or a material clad insulation layer.

Determination of the maximum exterior temperature of an insulated exhaust

component will depend on many factors, and is often difficult to predict without

specific knowledge of the exact service environment. Factors such as the ambient

temperature and air flow across the piping elements can greatly affect the heat flux

from the system and have a direct impact on the expected surface temperature of

the system.

SYSTEM EVALUATION

System noise

It is extremely important to evaluate the total system when specifying an

exhaust silencer for a specific installation. As we have discussed several factors

such as breakout, raw source levels and spatial constraints can play significant
24
roles in silencer selection and design. For example, a silencer might theoretically

reduce the exhaust noise of an engine to 60 dB at 10 feet without effectively

silencing or isolating the engine intake, mechanical casing noise, etc. Many

silencers have been incorrectly specified and installed in environments where the

measured noise level in the area is considerably higher than the level produced by

the silenced engine. A general knowledge of acoustics and sound will help in

identifying potential factors that could impact the overall noise levels of an

installation but a silencer manufacturer or acoustic consultant should be engaged

when an unknown or difficult situation arises. As a final evaluation of an installed

system the radiated sound pressure level at a given distance from the source

should be measured and compared against the acoustical specification.

System backpressure

It is essential to the performance of a generator set that the installed exhaust

system does not exceed the engine manufacturer's maximum exhaust

backpressure limit. Pressure drop of exhaust system includes losses due to piping,

silencer, and Termination. High backpressure can cause a decrease in engine

efficiency or increase in fuel consumption, overheating, and may result in a

complete shutdown of the generating system potentially causing significant

damage. Pressure drop is measured in a straight length of pipe 3 to 5 diameters

from the last transition change after the turbocharger outlet.

25
 CHAPTER 2

PRINCIPLE AND BLOCK DIAGRAM

WORKING PRINCIPLE

As the exhaust gases enters in to the aqua silencer, the perforated tube

converts high mass bubbles in lo low mass bubbles after that they passes through

charcoal layer which again purify the gases. It is highly porous

and possess extra free valences so it has high absorption capacity. After passing

over the charcoal layer some of the gases may dissolved in to the water and finally

the exhaust gases escape through the opening in to the atmosphere. Hence aqua

silencer reduces noise and pollution.

Figure 6 Working of Aqua Silencer

26
 BLOCK DIAGRAM

Figure 7 Block Diagram of Aqua Silencer

27
 CHAPTER 3

COMPONENTS AND DESCRIPTION

MATERIAL SELECTION

The proper selection of material for the different part of a machine is the main

objective in the fabrication of machine. For a design engineer it is must that he be

familiar with the effect, which the manufacturing process and heat treatment have

on the properties of materials. The Choice of material for engineering

purposes depends upon the following factors:

1. Availability of the materials.

2. Suitability of materials for the working condition in service.

3. The cost of materials.

4. Physical and chemical properties of material.

5. Mechanical properties of material.

The mechanical properties of the metals are those, which are associated with

the ability of the material to resist mechanical forces and load. We shall now

discuss these properties as follows:

1. Strength It is the ability of a material to resist the externally applied forces

2. Stress Without breaking or yielding. The internal resistance offered by a part

to an externally applied force is called stress.

3. Stiffness It is the ability of material to resist deformation under stresses. The

modules of elasticity of the measure of stiffness.

28
4. Elasticity it is the property of a material to regain its original shape after

deformation when the external forces are removed. This property is desirable for

material used in tools and machines. It may be noted that steel is more elastic than

rubber.

5. Plasticity it is the property of a material, which retain the deformation produced

under load permanently. This property of material is necessary for forging, in

stamping images on coins and in ornamental work.

6. Ductility it is the property of a material enabling it to be drawn into wire with the

application of a tensile force. A ductile material must be both strong and plastic.

The ductility is usually measured by the terms, percentage elongation and percent

reduction in area. The ductile materials commonly used in engineering practice are

mild steel, copper, aluminum, nickel, zinc, tin and lead.

7. Brittleness It is the property of material opposite to ductile. It is the property of

breaking of a material with little permanent distortion. Brittle materials when

subjected to tensile loads snap off without giving any sensible elongation. Cast iron

is a brittle material.

8. Malleability It is a special case of ductility, which permits material to be

rolled or hammered into thin sheets, a malleable material should be plastic but

it is not essential to be so strong. The malleable materials commonly used in

engineering practice are lead, soft steel, wrought iron, copper and aluminum.

9. Toughness it is the property of a material to resist the fracture due to high

impact loads like hammer blows. The toughness of the material decreases when it

is heated. It is measured by the amount of absorbed after being stressed up to the

29
point of fracture. This property is desirable in parts subjected to shock an impact

loads.

10. Resilience It is the property of a material to absorb energy and to resist rock

and impact loads. It is measured by amount of energy absorbed per unit volume

within elastic limit. This property is essential for spring material.

11. Creep when a part is subjected to a constant stress at high temperature for

long period of time, it will undergo a slow and permanent deformation called creep.

This property is considered in designing internal combustion engines, boilers and

turbines.

12. Hardness It is a very important property of the metals and has a wide verity of

meanings. It embraces many different properties such as resistance to wear

scratching, deformation and Mach inability etc. It also means the ability of the metal

to cut another metal. The hardness is usually expressed in numbers, which are

dependent on the method of making the test. The hardness of a metal may be

determined by the following test.

a) Brunel hardness test

b) Rockwell hardness test

c) Vickers hardness (also called diamond pyramid) test.

The science of the metal is a specialized and although it overflows in to

realms of knowledge it tends to shut away from the general reader. The

knowledge of materials and their properties is of great significance for a design

engineer. The machine elements should be made of such a material which has

properties suitable for the conditions of operations. In addition to this a design

30
engineer must be familiar with the manufacturing processes and the heat

treatments have on the properties of the materials. In designing the various

part of the machine it is necessary to know how the material will function in

service. For this certain characteristics or mechanical properties mostly used

in mechanical engineering practice are commonly determined from standard

tensile tests. In engineering practice, the machine parts are subjected to various

forces, which may be due to either one or more of the following.

1. Energy transmitted

2. Weight of machine

3. Frictional resistance

4. Inertia of reciprocating parts

5. Change of temperature

6. Lack of balance of moving parts

The selection of the materials depends upon the various types of stresses

that are set up during operation. The material selected should with stand it. Another

criteria for selection of metal depend upon the type of load because a machine part

resist load more easily than a live load and live load more easily than a shock load.

Selection of the material depends upon factor of safety, which in turn

depends upon the following factors.

1. Reliabilities of properties

2. Reliability of applied load

3. The certainty as to exact mode of failure

31
 4. The extent of simplifying assumptions

5. The extent of localized

6. The extent of initial stresses set up during manufacturing

7. The extent loss of life if failure occurs

8. The extent of loss of property if failure occurs

Reasons for using Material as a Mild Steel

1. Mild steel is readily available in market

2. It is economical to use

3. It is available in standard sizes

4. It has good mechanical properties i.e. it is easily Machin able

5. It has moderate factor of safety, because factor of safety results

in unnecessary wastage of material and heavy selection. Low factor of safety

results in unnecessary risk of failure

6. It has high tensile strength

7. Low co-efficient of thermal expansion

Properties of Mild Steel

M.S. has a carbon content from 0.15% to 0.30%. They are easily wieldable

thus can be hardened only. They are similar to wrought iron in properties. Both

ultimate tensile and compressive strength of these steel increases with increasing

carbon content. They can be easily gas welded or electric or arc welded. With

increase in the carbon percentage weld ability decreases.

32
 Mild steel serve the purpose and was hence was selected because of the

above purpose

BRIGHT MATERIAL It is a machine drowned. The main basic difference between

mild steel and bright metal is that mild steel plates and bars are forged in the forging

machine by means is not forged. But the materials are drawn from the dies in the

plastic state. Therefore the material has good surface finish than mild steel and has

no carbon deposits on its surface for extrusion and formation of engineering

materials thus giving them a good surface finish and though retaining their metallic

properties

. COMPONENTS

1. Perforated Tube

2. Charcoal

3. Lime Water

4. Non Return Valve

5. H-Nipple

33
 CHARCOAL

Charcoal is the dark grey residue consisting of carbon, and any remaining

ash, obtained by removing water and other volatile constituents from animal and

vegetation substances. Charcoal is usually produced by slow pyrolysis, the heating

of wood or other substances in the absence of oxygen (see pyrolysis, char and

biochar). It is usually an impure form of carbon as it contains ash; however, sugar

charcoal is among the purest forms of carbon readily available, particularly if it

is not made by heating but by a dehydration reaction with sulfuric acid to minimize

introducing new impurities, as impurities can be removed from the sugar in

advance. The resulting soft, brittle, lightweight, black, porous material resembles

coal.

Types:

Commercial charcoal is found in either lump, briquette, or extruded forms:

Lump charcoal is made directly from hardwood material and usually produces far

less ash than briquettes.

Briquettes are made by compressing charcoal, typically made from sawdust and

other wood by-products, with a binder and other additives. The binder is usually

starch. Some briquettes may also include brown coal (heat source), mineral carbon

(heat source), borax, sodium nitrate (ignition aid), limestone (ash-whitening agent),

raw sawdust (ignition aid), and other additives like paraffin or petroleum solvents to

aid in ignition.

34
Extruded charcoal is made by extruding either raw ground wood or carbonized

wood into logs without the use of a binder. The heat and pressure of the extruding

process hold the charcoal together. If the extrusion is made from raw wood material,

the extruded logs are then subsequently carbonized.

Japanese charcoal removes pyro ligneous acid during the charcoal making.

Therefore when burning, there are almost no stimulating smells or smoke. The

charcoal of Japan is classified into three kinds.

 White Charcoal

 Black Charcoal

 Oaten Charcoal

Black charcoal that is made from hardened sawdust.

The characteristics of charcoal products (lump, briquette, or extruded forms)

vary widely from product to product. Thus it is a common misconception to

stereotype any kind of charcoal, saying which burns hotter, etc.

 Bamboo charcoal

 Activated Carbon

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 Purification and filtration

Charcoal may be activated to increase its effectiveness as a filter. Activated

charcoal readily adsorbs a wide range of organic compounds dissolved or

suspended in gases and liquids. In certain industrial processes, such as the

purification of sucrose from cane sugar, impurities cause an undesirable color,

which can be removed with activated charcoal. It is also used to absorb odors and

toxins in gases, such as air. Charcoal filters are also used in some types of gas

masks. The medical use of activated charcoal is mainly the adsorption of poisons,

especially in the case of suicide attempts in which the patient has ingested a large

amount of a drug. Activated charcoal is available without a prescription, so it is used

for a variety of health-related applications. For example, it is often used to reduce

discomfort (and embarrassment) due to excessive gas in the digestive tract.

Animal charcoal or bone black is the carbonaceous residue obtained by the

dry distillation of bones. It contains only about 10% carbon, the remainder being

calcium and magnesium phosphates (80%) and other inorganic material originally

present in the bones. It is generally manufactured from the residues obtained in the

glue and gelatin industries. Its decolorizing power was applied in 1812 by Deron to

the clarification of the syrups obtained in sugar refining; but its use in this direction
36
has now greatly diminished, owing to the introduction of more active and easily

managed reagents. It is still used to some extent in laboratory practice. The

decolorizing power is not permanent, becoming lost after using for some time; it

may be revived, however, by washing and reheating. Wood charcoal also to some

extent removes coloring material from solutions, but animal charcoal is generally

more effective.

PERFORATED TUBE

The main function of the perforated tube is to suppress the sound and

increase the performance. Number of holes is provided on the surface of the tube.

It is used to convert high mass bubbles to low mass bubbles. The charcoal layer is

pasted over the perforated tube. The exhaust gas from the engine cylinder is

passed through these holes so large gas bubbles are converted to smaller gas

bubbles. Hence the noise is reduced. Perforated tube is an essential part of an

aqua filter silencer.

Figure 9 Perforated Tube

37
 Figure 9 Graph Backpressure (Pa) vs. Hole Diameter (mm)

LIME WATER

Lime water is the common name for a saturated solution of calcium

hydroxide. Calcium hydroxide, Ca(OH)2 is sparsely soluble in water (1.5 g/L at 25

°C) Pure limewater is clear and color less, with a slight earthy smell and an alkaline

bitter taste of calcium hydroxide. The term lime refers to the alkaline mineral, and

is unrelated to the acidic fruit. Limewater is prepared by stirring excess calcium

hydroxide in pure water, and filtering off the excess insoluble Ca(OH)2 . When

excess calcium hydroxide is added to limewater, a suspension of calcium hydroxide

particles remains, giving it a milky aspect, in which case it has the common name

of milk of lime. Milk of lime is an alkaline solution with a pH of 12.3.

38
 Calcium hydroxide, traditionally called slaked lime, is an inorganic

compound with the chemical formula Ca(OH)2. It is a color less crystal or white

powder and is obtained when calcium oxide (called lime or quicklime) is mixed, or

slaked with water. It has many names including hydrated lime, caustic lime,

builder’s lime, slack lime, or pickling lime. Calcium hydroxide is used in many

applications, including food preparation. Limewater is the common name for a

saturated solution of calcium hydroxide. A suspension of fine calcium hydroxide

particles in water is called milk of lime. The solution is called limewater and is a

medium strength base that reacts with acids and attacks many metals.

NON RETURN VALVE

The non-return valve is a mechanical device a valve, which normally allows

fluid (liquid or gas) to flow through it in only one direction. The Aqua silencer was

filled with water and it is directly connected to the exhaust pipe of the engine. There

is a chance for the water to get enter into the engine cylinder. To avoid this, Non

return valve is used. It allows the flow of fluid in one direction only

39
 H-Nipple

It is a device which is used to connect two pipes together. It consists of two

threaded sides.

40
 WATER TREATMENT

ABSORPTION PROCESS

Activated charcoal is available in granular or powdered form. As it is highly

porous and possess free valences. So it possess high absorption capacity. Activated

carbon is more widely used for removal of taste and odorous from the public water

supplies because it has excellent properties of attracting gases, finely divided solid

particles and phenol type impurities, The activated carbon, usually in the powdered

form is added to the water either before or after the coagulation with sedimentation.

But it is always saddled before filtration. Feeding devices are similar to those used

in feeding the coagulants.

ADVANTAGES OF ABSORPTION PROCESS.

 It increases the coagulation power of the process. Its use reduces the

chlorine demand. The excessive dose of activated carbon is not harmful.

 The treatment process is very simple and it requires nearly no skill. The

efficiency of removing color, odor and taste is quite high.

 It can be easily regenerated It has excellent properties of attracting gases

LIME WATER WASH METHOD

The water is a good absorbing medium. In aqua silencer the gases are

made to be dissolved in water. When these gases dissolved in water they form

acids, carbonates, bicarbonates etc.

41
 Action of dissolved SO2:-

When Sox is mixed in water, it form SO 2, SO3, SO4, H2SO4, H2SO, i.e.

sulfur Acid (H2SO3,), it forms Hydrogen Supplied which causes fowl rotten egg

smell, acidify and corrosion of metals.

Action of dissolved CO2:-

The dissolved carbon dioxide forms bicarbonate at lower PH and

Carbonates at higher PH. This levels 40-400 mg/liter. The form a scale in pipes and

boilers. The carbon dioxide mixes with water to form Carbonic acid. It is corrosive

to metals and causes greenhouse effect.

Effect of dissolved NOx:-

The Nitrogen in water undergoes oxidation to form ammonia Nitrate, Nitrite,

Nitric acid. This synthesis of protein amino acids is affected by Nitrogen. Nitrate

usually occurs in trace quantities in surface water. A limit of 10mg per liter Nitrate

is affordable in drinking water.

42
CAD MODELS OF SILENCER

Figure ISOMETRIC VIEW

Figure SECTION VIEW

43
 CHAPTER 4

METHODOLOGY

44
 CHAPTER 6

LIST OF EQUIPMENT AND COST ESTIMATION

RAW MATERIAL AND STANDARD MATERIAL

SR. No PART MATERIAL QUANTITY

1 Outer Shell MS 1

2 Perforated Tube MS 2

3 Mesh SS 1

4 Glass Wool GW 1

5 Non-Return Valve Brass 1

6 Activated Charcoal Carbon 1

7 Lime Water Lime 300ML

8 Pipe MS 4

9 Drain Plug MS 2

10 Welding Rods - 8

11 Paint - 1Lit

45
 COST ESTIMATION

Cost estimation may be defined as the process of forecasting the expenses

that must be incurred to manufacture a product. These expenses take into a

consideration all expenditure involved in a design and manufacturing with all

related services facilities such as pattern making, tool, making as well as a

portion of the general administrative and selling costs.

PURPOSE OF COST ESTIMATING

1. To determine the selling price of a product for a quotation or contract so as to

ensure a reasonable profit to the company.

2. Check the quotation supplied by vendors.

3. Determine the most economical process or material to manufacture the

product.

4. To determine standards of production performance that may be used to control

the cost.

BASICALLY THE BUDGET ESTIMATION IS OF TWO TYPES:

1. Material cost

2. Machining cost

MATERIAL COST ESTIMATION: Material cost estimation gives the total

amount required to collect the raw material which has to be processed or

fabricated to desired size and functioning of the components.

These materials are divided into two categories.

1. Material for fabrication:

46
 In this the material in obtained in raw condition and is manufactured or

processed to finished size for proper functioning of the component.

2. Standard purchased parts:

This includes the parts which was readily available in the market like Allen

screws etc. A list is forecast by the estimation stating the quality, size and

standard parts, the weight of raw material and cost per kg. For the fabricated

parts.

MACHINING COST ESTIMATION

This cost estimation is an attempt to forecast the total expenses that may

include to manufacture apart from material cost. Cost estimation of manufactured

parts can be considered as judgment on and after careful consideration which

includes labor, material and factory services required to produce the required part.

PROCEDURE FOR CALCULATION OF MATERIAL COST:

The general procedure for calculation of material cost estimation is

1. After designing a project a bill of material is prepared which is divided into two

categories.

a. Fabricated components

b. Standard purchased components

2. The rates of all standard items are taken and added up.

3. Cost of raw material purchased taken and added up.

Cost of project = (A) material cost + (B) Machining cost + (C) labor cost
47
(A) Material cost is calculated as under

I) Raw material cost

II) Finished product cost

I) Raw material cost:-

It includes the material in the form of the Material supplied by the “

Steel authority of India limited” and ‘Indian aluminum co.,’ as the round

bars, angles, square rods , plates along with the strip material form. We

have to search for the suitable available material as per the requirement of

designed safe values.

48
 RAW MATERIAL AND STANDARD MATERIAL COSTS

SR. No PART MATERIAL QUANTITY COST

1 Outer Shell MS 1 600

2 Perforated Tube MS 1 200

3 Mesh SS 2 30

4 Glass Wool GW 1 120

5 Non-Return Valve Brass 1 420

6 Activated Charcoal Carbon 1 30

7 Lime Water Lime 300ML 80

8 Pipe MS 4 80

9 Drain Plug MS 2 20

10 Welding Rods - 8 120

11 Paint - 1Lit 120

Total 1820

49
 RESULTS AND DISCUSSION

Figure PUC Without Aqua Silencer for Bullet 350

Figure PUC With Aqua Silencer for Bullet 350

50
 GRAPHICAL DATA

speed
1.6

1.4

1.2

0.8

0.6

0.4

0.2

0
0 20 40 60 80 100 120

CO Vs SPEED WITHOUT AQUA SILENCER

speed
1.4

1.2

0.8

0.6

0.4

0.2

0
0 20 40 60 80 100 120

CO Vs SPEED WITH AQUA SILENCER

51
LIQUID CONSERVATION

By experimentation it was noted that the conservation of liquid for a

bullet classic 350 at a normal speed of 40 Kmph within a time of one

hour was roughly 15 millilitres.

PHOTOGRAPHY

52
53
 ADVANTAGES AND FUTURE SCOPE

ADVANTAGES

 No Vibration when engine is running.

 Start the Engine very easily.

 Sound is reduced

 Low Cost compared to normal silencer

 Control Emission and noise in greater level

 Carbon is precipitated

 CO is reduced 60 % to 70 % compared to normal silencer

54
 FUTURE SCOPE

There has understandably been an increasing concern in recent years over

the increasing rate of transportation and discharge of industrial waste waters into

environment as well as the release of toxic emission into the atmosphere from

Automobile and industrial engines. Technological breakthroughs like the Aqua

Silencer can be the answer to the reduction of toxic emissions into the environment

from engines. Currently, the Aqua Silencer is only suitable for use in industrial

engines and heavy weight vehicles. But R&D departments have taken the subject

into consideration and are going into developing and redesigning the Aqua Silencer

to make it possible to be fitted in to automobiles keeping its Aerodynamic properties

stable and sustaining or increasing its efficiency.

55
 CONCLUSION

 The aqua silencer is more effective in the reduction of emission gases from

the engine reduction of emission gases from the engine

 Exhaust using perforated tube and charcoal, by using perforated tube the

backpressure will remain constant and the sound level is reduced.

 By using perforated tube the fuel remains same as conventional system.

 By using water as a medium the sound can be lowered and also by using

activated charcoal in water we can control the exhaust emission to a

greater level.

 It is smokeless and pollution free emission and also it is very cheap. This

aqua silencer’s performance is almost equivalent to the conventional

56
 silencer. It can be also used both for two wheelers and four wheelers and

also can be used in industries.

BIBILIOGRAPHY

 WWW.GOOGLE.COM/AQUASILENCER

 Design and Fabrication of Aqua Silencer for I.C Engines by Ajay Kumar

Dhiman , Prakash Joshi Journal from International Journal of Recent

Innovation in Engineering and Reasearch.

 Development of Emission and Noise Control Device from International

Journal of Modern Trends in Engineering and Research.

 www.scribd.com

 Engg.Chemistry- Jain and Jain

 https://Exhaustsilencers.com

 IC Engines- Ganeshan

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