A welded exhaust header for an inline 4-cylinder engine

// Exhaust Manifold
// A welded exhaust header for an inline 4-cylinder engine
// Categories: Automotive & Transportation; Mechanical Components

// Set units
@settings(defaultLengthUnit = in, kclVersion = 2.0)

// Define parameters
primaryTubeDiameter = 1.625
wallThickness = 0.080
plateHeight = 0.125
bendRadius = 3
tubeWallMidRadius = primaryTubeDiameter / 2 - (wallThickness / 2)

// Draw a primary tube for each cylinder with specified lengths and angles
sweepPlane001 = {
  origin = [0.0, 0.0, 0.0],
  xAxis = [0.0, 1.0, 0.0],
  yAxis = [0.0, 0.0, 1.0]
}
pathSketch001 = sketch(on = sweepPlane001) {
  line1 = line(start = [var 0in, var 0.13in], end = [var -0.14in, var 3.08in])
  arc2 = arc(start = [var 2.45in, var 5.91in], end = [var -0.38in, var 3.04in], center = [var 3in, var 3.13in])
  coincident([line1.end, arc2.end])
  line3 = line(start = [var 3.19in, var 5.43in], end = [var 8.45in, var 7.02in])
  coincident([arc2.start, line3.start])
  arc4 = arc(start = [var 8.55in, var 7.14in], end = [var 10.95in, var 10.33in], center = [var 7.87in, var 10.08in])
  coincident([line3.end, arc4.start])
  line5 = line(start = [var 10.98in, var 10.53in], end = [var 10.42in, var 15.32in])
  coincident([arc4.end, line5.start])
  vertical(line1)
  verticalDistance([line1.start, line1.end]) == 3in
  vertical(line1)
  coincident([ORIGIN, line1.start])
  tangent([line3, arc2])
  tangent([line3, arc4])
  tangent([line5, arc4])
  verticalDistance([line1.start, line5.end]) == 15.3
  radius(arc2) == bendRadius
  radius(arc4) == bendRadius
  horizontalDistance([line1.start, line5.end]) == 10.4
  verticalDistance([line1.start, line3.start]) == 6
  horizontalDistance([line1.start, line3.start]) == 2.5
  horizontalDistance([line1.start, arc4.start]) == 8.65in
}

sectionPlane001 = {
  origin = [0.0, 0.0, 0.0],
  xAxis = [1.0, 0.0, 0.0],
  yAxis = [0.0, 1.0, 0.0]
}
sectionSketch001 = sketch(on = sectionPlane001) {
  circle1 = circle(start = [var 0.81in, var 0in], center = [var 0in, var -0.11in])
  circle2 = circle(start = [var 0.73in, var 0in], center = [var -0.07in, var 0.03in])

  horizontalDistance([circle2.center, circle2.start]) == tubeWallMidRadius
  coincident([circle2.center, ORIGIN])
  coincident([circle1.center, circle2.center])
  horizontalDistance([circle2.center, circle1.start]) == primaryTubeDiameter / 2
  line1 = line(start = [var -0in, var -0in], end = [var 0.77in, var 0in], construction = true)
  coincident([line1.start, circle2.center])
  coincident([line1.end, circle2.start])
  horizontal(line1)
  line2 = line(start = [var 0.77in, var -0in], end = [var 0.81in, var 0in], construction = true)
  coincident([line2.start, circle2.start])
  coincident([line2.end, circle1.start])
  horizontal(line2)
}
sectionRegion001 = region(segments = [sectionSketch001.circle1])
primaryTube001 = sweep(sectionRegion001, path = pathSketch001)
hide(sectionSketch001)
hide(pathSketch001)

// Clone the first tube and apply the slight angle offset for the second cylinder
primaryTube002 = clone(primaryTube001)
  |> rotate(axis = [0, 0, 1], angle = -1deg)
  |> translate(x = 2, global = true)

// Draw the third primary tube
sweepPlane002 = {
  origin = [4.0, 0.0, 0.0],
  xAxis = [sin(-24.3deg), cos(-24.3deg), 0.0],
  yAxis = [0.0, 0.0, 1.0]
}
pathSketch003 = sketch(on = sweepPlane002) {
  line1 = line(start = [var 0in, var 0.125in], end = [var 0in, var 5.125in])
  arc2 = arc(start = [var 2.47905547in, var 8.07942326in], end = [var 0in, var 5.125in], center = [var 3in, var 5.125in])
  coincident([line1.end, arc2.end])
  line3 = line(start = [var 2.47905547in, var 8.07942326in], end = [var 7.40309401in, var 8.94766401in])
  coincident([arc2.start, line3.start])
  arc4 = arc(start = [var 7.40309401in, var 8.94766401in], end = [var 9.87072787in, var 12.16355325in], center = [var 6.88214948in, var 11.90208728in])
  coincident([line3.end, arc4.start])
  line5 = line(start = [var 9.87072787in, var 12.16355325in], end = [var 9.60926191in, var 15.15213727in])
  coincident([arc4.end, line5.start])

  horizontalDistance([line1.start, ORIGIN]) == 0in
  verticalDistance([ORIGIN, line1.start]) == plateHeight - 0.005
  vertical(line1)
  verticalDistance([line1.start, line1.end]) == 5in
  tangent([line1, arc2])
  tangent([line3, arc2])
  tangent([line3, arc4])
  tangent([line5, arc4])
  radius(arc2) == bendRadius
  radius(arc4) == bendRadius
  horizontalDistance([line1.start, line3.start]) == 2.47905547in
  verticalDistance([line1.start, line3.start]) == 7.95442326in
  horizontalDistance([line1.start, line3.end]) == 7.40309401in
  verticalDistance([line1.start, line3.end]) == 8.82266401in
  distance([line5.start, line5.end]) == 3in
  horizontalDistance([line1.start, line5.end]) == 9.61in
  verticalDistance([line1.start, line5.end]) == 15.03in
}

sectionPlane003 = {
  origin = [4.0, 0.0, 0.0],
  xAxis = [1.0, 0.0, 0.0],
  yAxis = [0.0, 1.0, 0.0]
}
sectionSketch003 = sketch(on = sectionPlane003) {
  circle1 = circle(start = [var 0.8125in, var 0in], center = [var 0in, var 0in])
  circle2 = circle(start = [var 0.7325in, var 0in], center = [var 0in, var 0in])

  horizontalDistance([circle2.center, circle2.start]) == tubeWallMidRadius
  verticalDistance([circle2.center, circle2.start]) == 0in
  coincident([circle2.center, ORIGIN])
  coincident([circle1.center, circle2.center])
  horizontalDistance([circle1.center, circle1.start]) == primaryTubeDiameter / 2
  verticalDistance([circle1.center, circle1.start]) == 0in
}
sectionRegion003 = region(segments = [sectionSketch003.circle1])
primaryTube003 = sweep(sectionRegion003, path = pathSketch003)
hide(sectionSketch003)
hide(pathSketch003)

// Clone the third tube and apply the final angle offset for the fourth cylinder
primaryTube004 = clone(primaryTube003)
  |> rotate(axis = [0, 0, 1], angle = -0.9deg)
  |> translate(x = 2, global = true)

// Create the mounting flange for the header
flangeSketch = sketch(on = XY) {
  line1 = line(start = [var 4.3in, var -1.25in], end = [var 1.7in, var -1.25in])
  arc2 = arc(start = [var 1.50716372in, var -1.17981333in], end = [var 1.7in, var -1.25in], center = [var 1.7in, var -0.95in])
  coincident([line1.end, arc2.end])
  arc3 = arc(start = [var 1.50716372in, var -1.17981333in], end = [var 0.35014602in, var -1.17981333in], center = [var 0.92865487in, var -1.86925333in])
  coincident([arc2.start, arc3.start])
  arc4 = arc(start = [var 0.15730974in, var -1.25in], end = [var 0.35014602in, var -1.17981333in], center = [var 0.15730974in, var -0.95in])
  coincident([arc3.end, arc4.end])
  line5 = line(start = [var 0.15730974in, var -1.25in], end = [var -1.24269026in, var -1.25in])
  coincident([arc4.start, line5.start])
  line6 = line(start = [var -1.24269026in, var -1.25in], end = [var -1.24269026in, var 1.35in])
  coincident([line5.end, line6.start])
  line7 = line(start = [var -1.24269026in, var 1.35in], end = [var 1.85730974in, var 1.35in])
  coincident([line6.end, line7.start])
  arc8 = arc(start = [var 2.05014602in, var 1.27981333in], end = [var 1.85730974in, var 1.35in], center = [var 1.85730974in, var 1.05in])
  coincident([line7.end, arc8.end])
  arc9 = arc(start = [var 2.05014602in, var 1.27981333in], end = [var 3.97850885in, var 1.27981333in], center = [var 3.01432743in, var 2.42888in])
  coincident([arc8.start, arc9.start])
  arc10 = arc(start = [var 4.17134513in, var 1.35in], end = [var 3.97850885in, var 1.27981333in], center = [var 4.17134513in, var 1.05in])
  coincident([arc9.end, arc10.end])
  line11 = line(start = [var 4.17134513in, var 1.35in], end = [var 7.27134513in, var 1.35in])
  coincident([arc10.start, line11.start])
  line12 = line(start = [var 7.27134513in, var 1.35in], end = [var 7.27134513in, var -1.25in])
  coincident([line11.end, line12.start])
  line13 = line(start = [var 7.27134513in, var -1.25in], end = [var 5.87134513in, var -1.25in])
  coincident([line12.end, line13.start])
  arc14 = arc(start = [var 5.67850885in, var -1.17981333in], end = [var 5.87134513in, var -1.25in], center = [var 5.87134513in, var -0.95in])
  coincident([line13.end, arc14.end])
  arc15 = arc(start = [var 5.67850885in, var -1.17981333in], end = [var 4.52149115in, var -1.17981333in], center = [var 5.1in, var -1.86925333in])
  coincident([arc14.start, arc15.start])
  arc16 = arc(start = [var 4.3in, var -1.25in], end = [var 4.52149115in, var -1.17981333in], center = [var 4.32567654in, var -0.94645056in])
  coincident([arc15.end, arc16.end])
  coincident([arc16.start, line1.start])

  circle17 = circle(start = [var 0.7325in, var 0in], center = [var 0in, var 0in])
  circle18 = circle(start = [var 2.7325in, var 0in], center = [var 2in, var 0in])
  circle19 = circle(start = [var 4.7325in, var 0in], center = [var 4in, var 0in])
  circle20 = circle(start = [var 6.7325in, var 0in], center = [var 6in, var 0in])
  circle21 = circle(start = [var -0.85in, var -0.975in], center = [var -0.975in, var -0.975in])
  circle22 = circle(start = [var 1.1in, var 0.975in], center = [var 0.975in, var 0.975in])
  circle23 = circle(start = [var 5.15in, var 0.975in], center = [var 5.025in, var 0.975in])
  circle24 = circle(start = [var 7.1in, var -0.975in], center = [var 6.975in, var -0.975in])

  horizontalDistance([ORIGIN, line1.start]) == 4.3in
  verticalDistance([line1.start, ORIGIN]) == 1.25in
  horizontalDistance([ORIGIN, line1.end]) == 1.7in
  verticalDistance([line1.end, ORIGIN]) == 1.25in
  horizontalDistance([ORIGIN, arc2.start]) == 1.50716372in
  verticalDistance([arc2.start, ORIGIN]) == 1.17981333in
  horizontalDistance([ORIGIN, arc2.center]) == 1.7in
  verticalDistance([arc2.center, ORIGIN]) == 0.95in
  horizontalDistance([ORIGIN, arc3.end]) == 0.35014602in
  verticalDistance([arc3.end, ORIGIN]) == 1.17981333in
  horizontalDistance([ORIGIN, arc3.center]) == 0.92865487in
  verticalDistance([arc3.center, ORIGIN]) == 1.86925333in
  horizontalDistance([ORIGIN, arc4.start]) == 0.15730974in
  verticalDistance([arc4.start, ORIGIN]) == 1.25in
  horizontalDistance([ORIGIN, arc4.center]) == 0.15730974in
  verticalDistance([arc4.center, ORIGIN]) == 0.95in
  horizontalDistance([line5.end, ORIGIN]) == 1.24269026in
  verticalDistance([line5.end, ORIGIN]) == 1.25in
  horizontalDistance([line6.end, ORIGIN]) == 1.24269026in
  verticalDistance([ORIGIN, line6.end]) == 1.35in
  horizontalDistance([ORIGIN, line7.end]) == 1.85730974in
  verticalDistance([ORIGIN, line7.end]) == 1.35in
  horizontalDistance([ORIGIN, arc8.start]) == 2.05014602in
  verticalDistance([ORIGIN, arc8.start]) == 1.27981333in
  horizontalDistance([ORIGIN, arc8.center]) == 1.85730974in
  verticalDistance([ORIGIN, arc8.center]) == 1.05in
  horizontalDistance([ORIGIN, arc9.end]) == 3.97850885in
  verticalDistance([ORIGIN, arc9.end]) == 1.27981333in
  horizontalDistance([ORIGIN, arc9.center]) == 3.01432743in
  verticalDistance([ORIGIN, arc9.center]) == 2.42888in
  horizontalDistance([ORIGIN, arc10.start]) == 4.17134513in
  verticalDistance([ORIGIN, arc10.start]) == 1.35in
  horizontalDistance([ORIGIN, arc10.center]) == 4.17134513in
  verticalDistance([ORIGIN, arc10.center]) == 1.05in
  horizontalDistance([ORIGIN, line11.end]) == 7.27134513in
  verticalDistance([ORIGIN, line11.end]) == 1.35in
  horizontalDistance([ORIGIN, line12.end]) == 7.27134513in
  verticalDistance([line12.end, ORIGIN]) == 1.25in
  horizontalDistance([ORIGIN, line13.end]) == 5.87134513in
  verticalDistance([line13.end, ORIGIN]) == 1.25in
  horizontalDistance([ORIGIN, arc14.start]) == 5.67850885in
  verticalDistance([arc14.start, ORIGIN]) == 1.17981333in
  horizontalDistance([ORIGIN, arc14.center]) == 5.87134513in
  verticalDistance([arc14.center, ORIGIN]) == 0.95in
  horizontalDistance([ORIGIN, arc15.end]) == 4.52149115in
  verticalDistance([arc15.end, ORIGIN]) == 1.17981333in
  horizontalDistance([ORIGIN, arc15.center]) == 5.1in
  verticalDistance([arc15.center, ORIGIN]) == 1.86925333in
  horizontalDistance([ORIGIN, arc16.center]) == 4.32567654in
  verticalDistance([arc16.center, ORIGIN]) == 0.94645056in

  coincident([circle17.center, ORIGIN])
  horizontalDistance([circle17.center, circle17.start]) == 0.7325in
  verticalDistance([circle17.center, circle17.start]) == 0in

  horizontalDistance([ORIGIN, circle18.center]) == 2in
  verticalDistance([ORIGIN, circle18.center]) == 0in
  horizontalDistance([circle18.center, circle18.start]) == 0.7325in
  verticalDistance([circle18.center, circle18.start]) == 0in

  horizontalDistance([ORIGIN, circle19.center]) == 4in
  verticalDistance([ORIGIN, circle19.center]) == 0in
  horizontalDistance([circle19.center, circle19.start]) == 0.7325in
  verticalDistance([circle19.center, circle19.start]) == 0in

  horizontalDistance([ORIGIN, circle20.center]) == 6in
  verticalDistance([ORIGIN, circle20.center]) == 0in
  horizontalDistance([circle20.center, circle20.start]) == 0.7325in
  verticalDistance([circle20.center, circle20.start]) == 0in

  horizontalDistance([circle21.center, ORIGIN]) == 0.975in
  verticalDistance([circle21.center, ORIGIN]) == 0.975in
  horizontalDistance([circle21.center, circle21.start]) == 0.125in
  verticalDistance([circle21.center, circle21.start]) == 0in

  horizontalDistance([ORIGIN, circle22.center]) == 0.975in
  verticalDistance([ORIGIN, circle22.center]) == 0.975in
  horizontalDistance([circle22.center, circle22.start]) == 0.125in
  verticalDistance([circle22.center, circle22.start]) == 0in

  horizontalDistance([ORIGIN, circle23.center]) == 5.025in
  verticalDistance([ORIGIN, circle23.center]) == 0.975in
  horizontalDistance([circle23.center, circle23.start]) == 0.125in
  verticalDistance([circle23.center, circle23.start]) == 0in

  horizontalDistance([ORIGIN, circle24.center]) == 6.975in
  verticalDistance([circle24.center, ORIGIN]) == 0.975in
  horizontalDistance([circle24.center, circle24.start]) == 0.125in
  verticalDistance([circle24.center, circle24.start]) == 0in
}
flangeRegion = region(segments = [flangeSketch.line1, flangeSketch.arc2], direction = CW)
flangeExtrude = extrude(flangeRegion, length = plateHeight)
hide(flangeSketch)

flangeTopLeftFillet = fillet(
  flangeExtrude,
  radius = 1.5,
  tags = [
    getCommonEdge(faces = [
      flangeRegion.tags.line6,
      flangeRegion.tags.line7
    ])
  ],
)
flangeTopFillets = fillet(
  flangeTopLeftFillet,
  radius = 1.5,
  tags = [
    getCommonEdge(faces = [
      flangeRegion.tags.line11,
      flangeRegion.tags.line12
    ])
  ],
)
flangeBottomLeftFillet = fillet(
  flangeTopFillets,
  radius = 0.25,
  tags = [
    getCommonEdge(faces = [
      flangeRegion.tags.line5,
      flangeRegion.tags.line6
    ])
  ],
)
flangeBody = fillet(
  flangeBottomLeftFillet,
  radius = 0.25,
  tags = [
    getCommonEdge(faces = [
      flangeRegion.tags.line12,
      flangeRegion.tags.line13
    ])
  ],
)


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