VU MotorsportsIntake/Exhaust Team

Kristina KitkoMark MelaskyPerry PetersonTim Wranovix

Project Description

• Design and build a new intake and/or exhaust system for the 2008 Formula SAE racecar

• Prepare a design report to be used in the FSAE 2008 Competition in Detroit

Problems with Current Naturally Aspirated System

• 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 do to lack of appropriate testing and modeling

Problems with Current Naturally Aspirated System (cont’d)

• Intake was made from spare parts in one day

• Exhaust system is very heavy– FSAE team is using the stock muffler from the

Honda motorcycle (8.5 pounds)– Total system weighs around 25 pounds

Constraints

• Described in FSAE rules:– 20mm Venturi restrictor on intake – 110 dB max exhaust volume

• Packaging:– Fit within rear of car (image on next slide)– Air filter, throttle, restrictor, fuel rail and muffler

mounts • Cost:

– Team must report market values of components used

Deliverables

• Finished intake and/or exhaust system that is ready to be mounted on the 2008 FSAE car by April 1.

• Detailed design report – Technical data with flow modeling– Images

Options

• Naturally Aspirated– Build intake and/or exhaust

• Turbocharged– Build intake and exhaust

Forced Induction

• Increases the pressure in the intake manifold forcing more air into the cylinder for combustion

• More gas combines with the air and produces a bigger explosion, increasing the engine’s horsepower

How Natural Aspiration Works

• Independent intake and exhaust • A vacuum is created when the piston goes

from the top of the cylinder to the bottom of the cylinder, drawing in air and fuel from the intake manifold

• Using geometry, the Helmholtz resonance can be incorporated to create a mild forced induction

How Natural Aspiration Works (continued)

• Exhaust pipes go from each cylinder to a collector (picture on next slide)

• The collector then tapers into a smaller diameter pipe that is connected to the muffler

• The taper chokes the exhaust gases, creating a Helmholtz resonance

• The pipes from each header need to be equal length to utilize the resonance

• Pros– FSAE engine is setup

for natural aspiration– Cheaper than forced

induction system– Intake and/or exhaust

can be redesigned– No moving parts, so

less likely to fail– Not pressurized

• Cons– Less power than

complete forced induction

– Geometry needs to be thoroughly calculated

How Turbos Work

• Turbos use exhaust gas to spin a turbine• A shaft connects the turbine to a

compressor • The compressor pressurizes air in the

intake manifold, causing forced induction– Complete system image on next slide

Garrett Turbocharger

• GT-12 (image on next slide)– Engine horsepower 50 - 130 – Displacement 0.4L - 1.2L

• FSAE team uses Honda CBR 600 (0.6L) producing 65 horsepower

• Free for any Formula SAE team– Must still be reported as purchased in cost

report

• Pros– Increased power– Intake and exhaust are

designed as one system

– Simpler geometry compared to a naturally aspirated system

– Widens engine’s power band

• Cons– Expensive– Heavy– Turbo lag– Current FSAE high

compression pistons need to be replaced

– Too much power makes the car harder to drive

Next Step

• Criterion for design decision: – Cost– Complexity– Design team knowledge– FSAE team input

Questions?