Vanderbilt Motorsports Intake System Design Fabrication April

Vanderbilt Motorsports Intake System Design & Fabrication April 10, 2008 Presentation Kristina Kitko Mark Melasky Perry Peterson Tim Wranovix 3/16/2018 1

Project Description Design and Fabrication of a new Intake System for the 2008 Formula SAE car. Deliverables: A new intake system All attachments and mounts A detailed design report 3/16/2018 2

Design Motivation • Inadequate data describing the intake and exhaust systems – FSAE team has suffered at competition due to lack of presentable data – FSAE team is unable to make improvements to current system due to lack of appropriate testing and modeling • Previous system was fabricated in one day without development of fabrication methodology

Design Constraints • Described in FSAE rules: – – • Packaging: – – • 20 mm Venturi restrictor on intake 110 d. B max exhaust volume Fit within rear of car Air filter, throttle, restrictor, fuel rail and muffler mounts Cost: – Team must report market values of components used

System Selection • Natural Aspiration – Car was designed for natural aspiration – Inexpensive compared to turbocharging – No moving parts – Requires thorough understanding of system geometry

Project Roadmap Venturi Restrictor • Design • Verification • Construction 3/16/2018 Conical Bend Plenum • Design • Verification • Construction Intake Runners Injector Bosses • Design • Verification • Construction 6

Project Roadmap Venturi Restrictor • Design • Verification • Construction 3/16/2018 Conical Bend Plenum • Design • Verification • Construction Intake Runners Injector Bosses • Design • Verification • Construction 7

Venturi Design: ASME Standard D 35 mm L 1 35 mm R 1 48. 125 mm α 1 21 R 2 72. 5 mm Dt 20 mm L 3 6. 67 mm R 3 100 mm α 2 7 R 4 100 mm L 5 35 mm Degrees

Diffuser Design: Flow Loss Curve for Venturi Design 3/16/2018 9

System Design: Pro. Engineer Rendering

System Fabrication: Venturi Restrictor 3/16/2018 11

Venturi Restrictor Modeling: Velocity Magnitude 3/16/2018 12

Venturi Restrictor Modeling: Y-Vorticity 3/16/2018 13

Flow Bench Testing: Results • 1 -year old venturi had lower pressure differential than 4 -year old venturi 3/16/2018 14

System Design: Pro. Engineer Rendering 3/16/2018 15

System Testing: Conical Bend 3/16/2018 16

Flow Bench Testing “No Nozzle Left Behind”

Project Roadmap Venturi Restrictor • Design • Verification • Construction 3/16/2018 Conical Bend Plenum • Design • Verification • Construction Intake Runners Injector Bosses • Design • Verification • Construction 18

Intake Manifold Design: Materials Analysis Fiberglass: • Hand-lain in one piece (in house) • Cost effective for cost report • Will still require aluminum parts to be machined separately 3/16/2018 19

System Fabrication: Intake Manifold 3/16/2018 20

System Design: Pro. Engineer Rendering 3/16/2018 21

Intake Manifold Design: Plenum Shape Comparison 3/16/2018 22

Project Roadmap Venturi Restrictor • Design • Verification • Construction 3/16/2018 Conical Bend Plenum • Design • Verification • Construction Intake Runners Injector Bosses • Design • Verification • Construction 23

System Design: Helmholtz Resonance Calculations • System idealization was 10, 000 RPM for Primary Tuning Peak • Results yielded 3 tuning peaks: – Primary Tuning Peak = 9876. 6 RPM – Helmholtz Tuning Peak =11, 704 RPM – Helmholtz Tuning Peak = 2021 RPM 3/16/2018 24

System Design: Pro. Engineer Rendering 3/16/2018 25

Intake Manifold Design: Fluent Verification 3/16/2018 26

System Fabrication: Intake Runners 3/16/2018 27

Project Roadmap Venturi Restrictor • Design • Verification • Construction 3/16/2018 Conical Bend Plenum • Design • Verification • Construction Intake Runners Injector Bosses • Design • Verification • Construction 28

System Design: Pro. Engineer Rendering 3/16/2018 29

System Integration: Intake System in Car 3/16/2018 30

Current Status • • Project to be completed on time Final assembly of components Paint Attach to FSAE car and Enjoy!