Kristina Kitko Mark Melasky Perry Peterson Tim Wranovix Vanderbilt Motorsports Intake System Design & Fabrication April 10, 2008 Presentation Kristina Kitko Mark Melasky Perry Peterson Tim Wranovix 7/31/2018

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 7/31/2018

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: Cost: 20mm Venturi restrictor on intake 110 dB max exhaust volume Packaging: 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 7/31/2018 Venturi Restrictor Design Verification Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018

Project Roadmap 7/31/2018 Venturi Restrictor Design Verification Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018

Venturi Design: ASME Standard 35 mm L1 R1 48.125 α1 21 Degrees R2 72.5 Dt 20 L3 6.67 R3 100 α2 7 R4 L5

Diffuser Design: Flow Loss Curve for Venturi Design 7/31/2018

System Design: ProEngineer Rendering

System Fabrication: Venturi Restrictor 7/31/2018

Venturi Restrictor Modeling: Velocity Magnitude 7/31/2018

Venturi Restrictor Modeling: Y-Vorticity 7/31/2018

Flow Bench Testing: Results 1-year old venturi had lower pressure differential than 4-year old venturi 7/31/2018

System Design: ProEngineer Rendering 7/31/2018

System Testing: Conical Bend 7/31/2018

Flow Bench Testing “No Nozzle Left Behind”

Project Roadmap 7/31/2018 Venturi Restrictor Design Verification Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018

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 7/31/2018

System Fabrication: Intake Manifold 7/31/2018

System Design: ProEngineer Rendering 7/31/2018

Intake Manifold Design: Plenum Shape Comparison 7/31/2018

Project Roadmap 7/31/2018 Venturi Restrictor Design Verification Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018

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 7/31/2018

System Design: ProEngineer Rendering 7/31/2018

Intake Manifold Design: Fluent Verification 7/31/2018

System Fabrication: Intake Runners 7/31/2018

Project Roadmap 7/31/2018 Venturi Restrictor Design Verification Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018

System Design: ProEngineer Rendering 7/31/2018

System Integration: Intake System in Car 7/31/2018

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