8th International Symposium

TRANSPORT NOISE AND VIBRATION

46 June 2006, St. Petersburg, Russia

Calculation and Design of Exhaust noise mufflers for Power

Engineering Equipment
Igolkin A.A., Kruchkov A.N., Shakhmatov E.V.
Institute of Acoustic of Mashine 443086, Samara, Moskovskoe shosse 34 iam@ssau.ru

ABSTRACT
The paper considers the main principles of reducing the noise of power engineering
equipment. The efficiency of using mufflers for reducing the exhaust noise of power
engineering equipment is justified. A design pattern of a pneumatic muffler is chosen.
mathematical model for calculating the level of noise of the pneumatic systems exhaust jet is
developed. The model takes into account the installation of a noise muffler. It describes the
impact of the noise muffler on the pneumatic systems fast acting. The results of simulating
transition processes in the pneumatic system are presented, taking into consideration the
installation of a noise muffler. Design data on pressure drop in the pneumatic capacity are
compared with the experimental data. On the basis of the model developed the exhaust noise
of power engineering equipment is calculated with and without a muffler.

INTRODUCTION
Noise control has become one of the most vital problems in present-day manufacture
including motor-car manufacture. Introduction of new technological processes, growth of
power and speed of technical equipment result in high-level noise man is constantly exposed
to. Creation of new types of industrial and automobiles with preset speed, power and load
parameters is often accompanied by the increase of general noise level and the expansion of
sound oscillation spectrum.
The noise of a pneumatic system, in particular, the noise of the exhaust of the exhaust jet
makes the greatest contribution to the general noise level in a working place. Figure 1 [1]
shows the spectra of noise generated during the operation of process equipment. From the
figure we notice that the exhaust of compressed air mares a significant contribution to the
general noise level of functioning equipment.
The noise of pneumatic systems appears mostly when compressed air issues from
pneumatic devices into the atmosphere due to turbulent mixing of high compressed air flow
with external air. Since the conditions of compressed air issue into the atmosphere are, as a
rule, supercritical, and the flow velocity is close to sound velocity, the level of noise during
the exhaust from the pneumodistributor may amount to 120130 dBA. The frequency
spectrum of the jet has a pronounced high-frequency nature with a maximum in the range
above 1000 Hz. The frequency with which sound pulses follow one another in a
pneumosystem, e.g. a press, corresponds to the number of working strokes of the hammer and
normally amounts to 70 90 cycles per minute. Thus, exhaust noise produced by press
pneumatic valves belongs to the category of discontinuous or impulse noises which affect
man most unfavorably.

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 L, dB

100
1

90

2
80
3

63 125 250 500 1000 2000 4000 8000 f, Hz

Figure 1. Level of press noise in

1. system upper die - billet lower die
2. pneumatic system
3. electric motor
In order to develop efficient pneumatic mufflers and to reduce the costs of their design and
finishing it is necessary to develop mathematical models and procedures for calculating such
devices.

1. CHOOSING MUFFLER DESIGN PATTERN

From the sources [2] we know that acoustic power W radiated by a cylindrical jet is
proportional to the jet velocity to the 6th 8th degree (depending on the value of velocity), the
square of air density in the jet and the square of jet diameter:

c2U cn D 2
W = k (M ) , (1)
0 c0m
where is density of jet medium;
U is efflux velocity;
D is the diameter of exhaust nozzle section;
0 is density of the environment;
0 is sound velocity
k (M ) - is proportionality factor
n, m are degree indices depending on efflux velocity

Air efflux parameter having the greatest impact on the level of generated noise is,
according to theoretical and experimental studies, efflux velocity [2]. Reducing efflux
conditions from = 1 to = 0,5 results in reducing noise level by approximately 24-25,
results according to Lighthill acoustic analogy (1). It is necessary to bear in mind, however,
that reducing efflux velocity excessively when designing mufflers leads inevitably to
considerable increase of the mufflers mass and size on the grounds of providing constant air
consumption. This will impose operational limitations on the muffler and in some cases will
make it impossible to use it for some kinds of process equipment.

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 Punched multichambered nozzles are frequently used as noise mufflers (see fig. 2).

Figure 2. Pattern of original jet transformation in a punched nozzle

The transformation of the original jet into a number of small jets aimed in different
directions from the original one also leads to noise reduction. Besides, additional effect is
attained due to the shift of jet noise spectrum at the muffler exit to the high-frequency region.
Analysis of flow structure in the area of mixing of the jets that issue from the punched
nozzle [2] shows that the flow can be presented schematically as two parts (see fig. 3). In the
first, or initial part the jets issue from each pipe without any interaction between them, that is,
independently of one another. The length of the initial part is determined by the diameter of
holes d, the distance between them, the conditions of air ejection between the pipes and the
exhaust flow issue conditions. The flow in the second or main part can be presented as part of
an equivalent circular jet the parameters of which are determined by the condition of
momentum constancy. Within the limits of the initial part outer jets shield the noise of inner
jets. As a result the intensity of sound radiation from the inner jets into the environment
weakens, and the overall acoustic energy of the initial part is smaller than the sum of acoustic
energies of all jets within the boundaries of this part. Maximum noise frequency of the initial
part is higher than the maximum frequency in the noise spectrum of the initial circular jet.
Increasing the number of holes and, consequently, reducing their diameter causes the shift of
noise spectrum to the region of higher frequencies. Maximum noise level reduction occurs
when the distance between the holes is equal to the hole diameters. Reducing the distance
between the holes brings about quick merging of separate small jets into a single turbulent
flow and, consequently, reduction of acoustic effect. Yet increasing the distance excessively
leads to the transformation of jets into a complex of standard free jets. In this case the sum of
acoustic capacities of the jets becomes equal to the acoustic capacity of the original jet. The
only acoustic effect of using a punched nozzle is, in fact, the shift of the exhaust flow noise
spectrum to the high-frequency region.

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 main part

Initial part
Uc

Figure 3. Pattern of exhaust flow issue from a punched nozzle

2. MATHEMATICAL MODEL OF EXHAUST NOISE MUFFLER.

Another factor, no less important than noise level reduction by using a muffler is the
impact of muffler installation on how fast the pneumatic system operates. Installing an
exhaust noise muffler is known to increase the time of emptying the pneumoreceiver, that is,
to reduce the speed of the systems operation. In some cases it is not acceptable according to
the specifications for pneumosystems. Besides, reducing the speed of a pneumosystem`s
operation, e.g. the operation of press equipment, may lead to industrial injuries.
In view of the above, in modeling a noise muffler it is essential to know not only the
amount of exhaust noise reduction, but also the parameters of the systems operation speed
after the noise muffler has been installed.
The mathematical model of an exhaust noise pneumatic muffler developed by the authors
is based on the equations of energy and compressed air motion in a pneumosestem`s elements
(fig. 4).

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 Figure 4. The main components of a noise muffler mathematical model

In developing the model following assumptions were taken:

Consumption coefficients of all passage sections are constant;
There is no heat exchange with the environment;
The flow is one-dimensional;
Neglect of parameter distribution;
The valve is opened without recoil.
A system of non-linear differential equations is written for each cavity of the
pneumosystem under consideration with a noise muffler installed. Let us next calculate the
aggregate acoustic power L , according to Lighthill`s formula which is emitted by a complex
of small jets flowing from the punched shells of the muffler Li :

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dpi = (G RT G RT ) k
dt i i 1 i i
Vi

2 8 2
W = c U c D
0c05
,

L = 101gK v + 181g ( p1 p ) 51gp + 181g ( K F / Z l ) + (2)

+ 40 + L + R
F m,
Li = 10 lg W + 20 lg r + 10 lg L

L = 10 lg(100,1L1 + 100,1L2 + ...100,1Li + ... + 100,1Ln )

where i is pressure in the cavity under consideration;

Gi is mass air consumption;
Ti is air temperature in the main line;
k is adiabatic indicator;
Vi is the volume of the cavity under consideration;
r is the distance from the receiver to the source of sound;
is the directivity factor;
L is the coefficient taking into account absorption of internal sources in muffler
elements;
is the coefficient taking into account noise reduction due to the interaction
of individual jets

3. CALCULATION OF NOISE MUFFLER CHARACTERISTICS

Figure 5 present the design of a noise muffler incorporated into a pneumosystem. On the
basis of the developed mathematical model transition processes in the pneumosystem were
calculated with regard to a noise muffler installed so as to investigate the impact of the
installed noise muffler on the speed of the pneumosystems operation.

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 D
D

muffler

L
Pneumosystem

S3

S2

Pneumoreceiver

0 V 0 S1

S0

Figure 5. Design scheme of a noise muffler incorporated into a pneumosystem

S0 cavity output section
S1 annular section of the valve section;
S2 section in the pneumodistributor;
S3 section in the pneumodistributor;
S4 holes of the central pipe;
S5 internal punching holes

Figure 6 presents the results of the theoretical investigation of noise muffler impact on
transition processes in pneumosystem.
It is obvious from figure 6 that with a noise muffler installed the time of pressure drop in
the pneumoreceiver increases, that is, the speed of the pneumosystem`s operation is reduced.
Increasing the time of pressure drop in pneumosystems e.g. forging presses results in double
working strokes which in its turn may be the cause of industrial injuries.

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 0,7

0,6
1

0, 5
P0 , MPa

2
0,4
3
0,3
t1
0,2
t

0 0,5 1 1,5 2 2,5 3

t, s

Figure 6. Design pressure dependences on the time of emptying

1 without a muffler;
2 with a muffler;
3 borderline (in speed of operation) curve of a transition process
For the pneumomuffler to conform to the standard GOST 25144-82 [5] the time of
pressure drop in a pneumocavity with a muffler is to meet the requirement:
t 1,4 t1, (3)

where t1 is the time of pressure drop during the exhaust without a muffler;
t is the time of pressure drop during the exhaust with a muffler.
To compare design dependence of pressure drop time in a pneumoreceiver with the
experimental data the following initial data were taken:
- initial pressure in pneumoreceiver p0=0.55 MPa
- pneumoreciever capacity V=250 l.
- the air issues through the muffler [4] with a connective size 2.

0.6
0.5
0.4
, MPa

0.3
0.2
0.1
0
0 0.5 1 1.5 2 2.5 3
t, sec

Figure 7. Dependence of pneumocapacity pressure on the time of emptying

____ design
+ experiment

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 Analysis of figure 7 shows good agreement of simulation results and experimental data.
Figure 8 presents design values of velocities through the elements of a pneumosystem with a
noise muffler installed depending on the relative area of external punching. It can be seen
from the graphs that the velocity through the valve remains practically constant for the whole
range of K2 and its value is considerably lower than that of the other velocities. With K2
increasing the velocity through the central pipe holes increases and becomes sonic when its
value is more than three. As this takes place, the velocity through the outer shell drops.
The velocity through the outer shell holes becomes equal to sound velocity in the range K2
=02. In view of the above, in calculating exhaust noise in a pneumosystem with a noise
muffler the noise generated by the valve is not taken unto account.

350
300
2
250
U, m /sec

200 1
3
150
10
50
0
min
0 2 2 4 6 8
2
Figure 8. Design values of efflux velocities through the elements of a pneumosystem
with a muffler according to the relative area of the outer shell:
1. through the pneumodistributor valve;
2. through the holes of the muffler central pipe;
3. through the holes of the muffler outer shell

Figure 9 presents a comparison of design and experimental dependences of pressure ratio

on the holes of the central pipe and those of the outer shell.

3
2 1
2,5

2
pi /pi+1

1,5

0,5

0 1 2 3 4 5 6 K2
min max
K
2 K
2

Figure 9. Comparison of design and experimental dependences of pressure ratio

on the holes of the central pipe (1) and those of the outer shell (2)
_____ design; experiment

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 Experimental points agree well with the theoretical curves. Thus, we found the range K2
within which critical efflux conditions do not exist.
On the basis of the developed model exhaust noise of a pneumosystem with and without a
muffler is computed. Figure 10 presents design dependence of noise level on time with and
without a muffler. Design efficiency of the noise muffler is 30dB which conforms to the
actual muffler construction [4].

1 2

100
L, dBA

50

L background

0
0,5 1 1,5 2 2,5 t, sec

Figure 10. Design values of exhaust noise level depending on the time
1 without a muffler; 2 with a muffler

CONCLUSION
A mathematical model is developed which makes it possible to calculate the efficiency of a
noise muffler and the time of pressure drop in a pneumoreceiver with regard to an exhaust
noise muffler installed. Design pressure dependences agree well with the experimental data,
which testifies to the adequacy of the proposed calculation procedure.

REFERENCES
1. A.P. Pyatidverny, A.I. Kudryavtsev, L.V. Solyanik, V.L. Ginsburg. Noise level
reduction using compressed air. Vestnic mashinostroyeniya, 1982, No. 11 pp. 15-17.
2. Aerodynamic sources of noise / A.G. Munin, V.M. Kuznetsov, Ye A. Leontiev.
Moscow; Mashinostroyeniye, 1981-248 pp.
3. Gerz Y.V. Dynamics of pneumatic system of machines. Mashinostroyeniye, 1985-
256 pp.
4. N.G. Zabolotny, A.N. Kruchkov, O.V. Nazarov, Ye. V. Shakhmatov, A.A. Igolkin.
Pneumomuffler. Certificate for a usable model No. 28189 of July, 10, 2002.
5. Standard GOST 25144-82. Pneumomuffler. Specifications. Izdatelstvo standartov,
1982.

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