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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
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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
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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
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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
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System Selection Natural Aspiration
Car was designed for natural aspiration Inexpensive compared to turbocharging No moving parts Requires thorough understanding of system geometry
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Project Roadmap 7/31/2018 Venturi Restrictor Design Verification
Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018
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Project Roadmap 7/31/2018 Venturi Restrictor Design Verification
Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018
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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
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Diffuser Design: Flow Loss Curve for Venturi Design
7/31/2018
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System Design: ProEngineer Rendering
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System Fabrication: Venturi Restrictor
7/31/2018
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Venturi Restrictor Modeling: Velocity Magnitude
7/31/2018
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Venturi Restrictor Modeling: Y-Vorticity
7/31/2018
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Flow Bench Testing: Results
1-year old venturi had lower pressure differential than 4-year old venturi 7/31/2018
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System Design: ProEngineer Rendering
7/31/2018
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System Testing: Conical Bend
7/31/2018
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Flow Bench Testing “No Nozzle Left Behind”
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Project Roadmap 7/31/2018 Venturi Restrictor Design Verification
Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018
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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
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System Fabrication: Intake Manifold
7/31/2018
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System Design: ProEngineer Rendering
7/31/2018
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Intake Manifold Design: Plenum Shape Comparison
7/31/2018
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Project Roadmap 7/31/2018 Venturi Restrictor Design Verification
Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018
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System Design: Helmholtz Resonance Calculations
System idealization was 10,000 RPM for Primary Tuning Peak Results yielded 3 tuning peaks: Primary Tuning Peak = RPM Helmholtz Tuning Peak =11,704 RPM Helmholtz Tuning Peak = 2021 RPM 7/31/2018
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System Design: ProEngineer Rendering
7/31/2018
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Intake Manifold Design: Fluent Verification
7/31/2018
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System Fabrication: Intake Runners
7/31/2018
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Project Roadmap 7/31/2018 Venturi Restrictor Design Verification
Construction Conical Bend Plenum Intake Runners Injector Bosses 7/31/2018
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System Design: ProEngineer Rendering
7/31/2018
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System Integration: Intake System in Car
7/31/2018
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Current Status Project to be completed on time
Final assembly of components Paint Attach to FSAE car and Enjoy!
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