Harmful gases that could damage the engine it also cleans up the gas is a bit before venting them into the air a properly functioning exhaust system does another big job muscling the airborne noise of the engine. And for that our ears thank them it’s a system of metal tubes and plates we only seem to notice when it breaks down and then the muffler’s importance is loudly driven home to make an exhaust system a mechanical polar draws a stainless steel strip up into a punch press shoveling it back and forth to allow for a precise cut with little waist the press bring 60 tons of force.
To bear as it pushes a steel into a dye it punches out a baffle shape with holes in it which will form the skeleton for the muffler box the finished baffles fall onto a conveyor and go into a storage cage now a long steel tube tumbles to automated blades would score the two crosswise to prevent denting. Then cut it to produce smaller tubes that go inside a muffler a circular saw descends on another tube to make a tailpipe its length depends on the type of muffler being made a loser machine spins and punctures one of the inside tubes the holes. Will regulate airflow in the muffler a CNC bending machine grips and bands a pipe in several spots this is how they make inlet intermediate and outlet tubes these tubes run the length of the exhaust system.
Then they place a tube in a circular hydraulic device which pinches the end down to a prescribed diameter to allow for further assembly a worker now places to baffles in a jig he fits the tubes through the holes in the baffles so that the tubes connect the baffles three mandrels slide into the tubes. The manuals expand locking the tubes to the baffles then they contract and slide out now the baffles and tubes are one piece next a robotic arm picks up metal sheets which will become the outer skin of the muffler box. It pushes them under an oval mold another armed with numerous rollers on it moves up and wraps the steel around the oval form then the middle block moves over the ends double folding them this locks them together and it completes.
The Assembly of the muffler’s outside skin magnets pick up the new skin and sliding on rails they relate to a mechanical claw which in turn feeds it to a flanger. The flanger bands the edges creating a lip on either end of the muffler skin a carousel turns and mechanical claw transfers the newly flange muffler skin to the stuffing position hydraulic pushers press the preassembled baffles.
And tubes inside the skin after the muffler is stuffed the robotic claw transfers it to a conveyor belt next a worker presses each end of the muffler against a set of Steel expansion fingers. The fingers move forward into holes in the muffler they expand and lock the baffles and tubes inside to form one solid internal unity grippers place the muffler on a spinning machine that will fasten the caps on rollers press against the flared edges of the revolving muffler tightly locking the end cap to the rest of the body. You see the rolling in slow motion it takes only a few revolutions to do the job ok then the rollers back away and a mechanical arm grabs the muffler and transfers it to a conveyor belt now these muscles are ready to help keep the traffic din at a minimum.