Formula SAE Intake System - VCU Scholars Compass
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Virginia Commonwealth University VCU Scholars Compass Capstone Design Expo Posters College of Engineering 2017 Formula SAE Intake System Esa Mahmood Virginia Commonwealth University Arman Sarwar Virginia Commonwealth University Michael R. Smith Virginia Commonwealth University Follow this and additional works at: hps://scholarscompass.vcu.edu/capstone Part of the Mechanical Engineering Commons , and the Nuclear Engineering Commons © e Author(s) is Poster is brought to you for free and open access by the College of Engineering at VCU Scholars Compass. It has been accepted for inclusion in Capstone Design Expo Posters by an authorized administrator of VCU Scholars Compass. For more information, please contact [email protected]. Downloaded from hps://scholarscompass.vcu.edu/capstone/186
Transcript of Formula SAE Intake System - VCU Scholars Compass
Virginia Commonwealth UniversityVCU Scholars Compass
Capstone Design Expo Posters College of Engineering
2017
Formula SAE Intake SystemEsa MahmoodVirginia Commonwealth University
Arman SarwarVirginia Commonwealth University
Michael R. SmithVirginia Commonwealth University
Follow this and additional works at: https://scholarscompass.vcu.edu/capstone
Part of the Mechanical Engineering Commons, and the Nuclear Engineering Commons
© The Author(s)
This Poster is brought to you for free and open access by the College of Engineering at VCU Scholars Compass. It has been accepted for inclusion inCapstone Design Expo Posters by an authorized administrator of VCU Scholars Compass. For more information, please contact [email protected].
Downloaded fromhttps://scholarscompass.vcu.edu/capstone/186
PurposeProduction Intake System:• Guide air into the engine• Allow sensor placement to measure airflow• Minimize unnecessary restriction in the form of
pressure drop
For the Formula SAE at VCU race team, this task isvery much the same, however:
1. All air going into the engine must pass through a20mm hole (nickel-sized)
2. The FSAE Intake is designed for use at 8,000 to12,000 RPM
3. The engine is from a CBR600 F4i motorcycle4. The part only needs to be produced in 250 units
DesignVelocity Stacks:Intended to smoothly funnel flow into a single tube,the velocity stacks (or trumpets) are critical inreducing pressure losses in the intake system. Aradius of 25mm was chosen.
Restrictor (Venturi):Required by the Society of Automotive Engineers(SAE), the 20mm restrictor is meant to bring thepeak power output down from 110hp to 75-85hp.Various diffusion angles were tested for pressureloss, and the 3 degree variation was chosen.
DesignPlenum:The plenum plays a major role in determiningmaximum power output and throttle response time,affecting drivability. Two geometries and 16 heightswere tested as a full assembly for pressure loss, andthe inline 150mm high plenum was chosen for itseasiness of construction and similar performance.
FabricationThe Mold:The ABS mold was 3D printed using Fused-Deposition Modeling, and formed the interior volumeof the plenum normally occupied by air.
Fiberglass:10 oz. fiberglass cloth and System 3000 High-TempEpoxy Resin were used to form 8 total layers ofcomposite, resulting in 0.25” wall thickness andstructural stability in continuous temperatures of upto 250°F.
Formula SAE Intake SystemMNE504 | Team members: Esa Mahmood, Arman Sarwar, Michael R. Smith | Faculty adviser: Charles Cartin, Ph.D.
Throttle Body
Restrictor
Top Plenum
Bottom Plenum
Runners
0
500
1000
1500
2000
2500
3000
0 5 10 15 20 25 30
Pres
sure
(Pa)
Radius (mm)
Pressure Difference vs. Trumpet RadiusTrumpet Radius Pressure (Pa) Iterations
0 mm 2623.63 1075 mm 1292.66 12810 mm 374.34 18215 mm 56.70 16420 mm 21.98 23825 mm 8.98 32930 mm 9.32 297
0
2000
4000
6000
8000
10000
3 4 5 6 7 8 9 10 11 12
Pres
sure
(Pa)
Diffusion Angle (Degrees)
Pressure Difference vs. Diffusion Angle Diffusion Angle Pressure (Pa) Iterations3 Degrees 3129.6 2114 Degrees 3425.9 2115 Degrees 4571.7 2046 Degrees 4409.8 1857 Degrees 5018.1 1948 Degrees 5736.1 1799 Degrees 6018.1 183
10 Degrees 6426.5 25111 Degrees 7197.7 20812 Degrees 7824.6 195
Plenum Height (mm)
Square Pressure Drop (kPa)
Percent Difference
Inline Pressure Drop (kPa)
50mm 10.67 -0.12% 10.6660mm 9.09 0.17% 9.1070mm 9.41 -0.53% 9.3680mm 10.16 0.95% 10.2690mm 9.79 1.10% 9.89
100mm 10.41 -0.77% 10.33110mm 10.14 3.52% 10.51120mm 9.63 1.65% 9.79130mm 10.18 -1.97% 9.98140mm 10.56 -3.06% 10.25150mm 10.91 -0.59% 10.84
It was decided that a denser calculation mesh and alarger array of heights were needed to find a betterrelationship between plenum height & pressure drop.
8.0
8.4
8.8
9.2
9.6
10.0
150 140 130 120 110 100 90 80 70 60 50
Pre
ssur
e (k
Pa)
Plenum Height (mm)
Pressure Difference 4mm3 Mesh
8.0
8.4
8.8
9.2
9.6
10.0
200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50
Pre
ssur
e D
iffer
ence
(kP
a)
Plenum Height (mm)
Pressure Difference 2mm3 Mesh
Carbon Fiber:3k carbon fiber constructionwas pursued for thealternative plenum. Vacuumbagging techniques wereused for a smoother finishand allow for more effectiveresin saturation.
CNC Lathe:The venturi was made at BGBTechnology using 6061 aluminumstock and a CNC lathe based ondrawings provided by the seniordesign team.
