Scholarlink

<p>Leakage testing is a necessary quality-assurance step for automotive fluid-handling parts to make sure that they are structurally sound and will work reliably. This study makes and tests an automated pneumatic fixture system that checks for leaks in elbow manifold parts. The suggested fixture uses a pneumatic clamping mechanism to make sure that the sealing stays the same during pressure decay testing at 3 bars. Finite element analysis (FEA) was performed to evaluate stress distribution, structural deformation, and the overall structural integrity of the fixture under operating conditions. To evaluate measurement repeatability, experimental validation was conducted on 25 cast manifold samples, with three repetitions for each specimen. Statistical analysis using standard deviation (SD) and coefficient of variation (CV) showed that the measurements were highly stable and demonstrated high repeatability. CV values below 1% showed very little variation. The developed pneumatic fixture demonstrated stable and repeatable leakage-testing performance with reduced operator dependency and improved process consistency during industrial testing operations. The results show that the proposed automated fixture-based leak-testing system is a reliable and cost-effective way to check elbow manifold parts for leaks.</p>

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Design, development and experimental validation of a pneumatic leakage testing fixture for automotive manifold components

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Pooja Prakash Mane,
  • V. A. Kamble,
  • Yogesh Sanjay Powar

摘要

Leakage testing is a necessary quality-assurance step for automotive fluid-handling parts to make sure that they are structurally sound and will work reliably. This study makes and tests an automated pneumatic fixture system that checks for leaks in elbow manifold parts. The suggested fixture uses a pneumatic clamping mechanism to make sure that the sealing stays the same during pressure decay testing at 3 bars. Finite element analysis (FEA) was performed to evaluate stress distribution, structural deformation, and the overall structural integrity of the fixture under operating conditions. To evaluate measurement repeatability, experimental validation was conducted on 25 cast manifold samples, with three repetitions for each specimen. Statistical analysis using standard deviation (SD) and coefficient of variation (CV) showed that the measurements were highly stable and demonstrated high repeatability. CV values below 1% showed very little variation. The developed pneumatic fixture demonstrated stable and repeatable leakage-testing performance with reduced operator dependency and improved process consistency during industrial testing operations. The results show that the proposed automated fixture-based leak-testing system is a reliable and cost-effective way to check elbow manifold parts for leaks.