Abstract-

Automotive system assemblies are mandated to have increased safety, reliability, emission/noise performance, comfort and value. Carbon dioxide regulations in CAFÉ norms from 130 g/km in 2017 to 113 g/km in 2022 change in base reference is very huge in terms of fuel efficiency improvement from 15% to 30% in 2022. Acoustic optimization in exhaust system with reduced back pressure needs a systematic development process. This paper establishes a systematic and sequential optimization process to improve engine performance with high fuel efficiency by tracing out the sensitive parameters in muffler that cause severity in achieving non-complimentary and imperative acoustic targets. 1D simulation tool GT-Power integrated with modeFRONTIER is used to execute several DOE (Design of Experiment) to optimize the muffler internals. 1.2L, 3 cylinder gasoline engine performances were analyzed and plotted in different pictorial analysis charts. As the result of statistic and optimized analysis 4 dB(A) noise reduction at 1500 rpm in 3rd order noise level with 14% reduced back pressure was achieved. Adopting the optimization technology reduces development stage by minimizing the number of iterations and it reduces the development cost.