Transcript Intake/Exhaust - Old Dominion University

Front Upright Team
Lloyd Outten
Joseph Perry
Rear Upright Team
Josh Carroll
Taylor Watkins
Intake & Exhaust Team
James Hogge
Rebekah McNally
Alisa Phillips
Henos Woldegiorgis
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Design Competition for Collegiate students
Represent ODU’s Engineering Department
8 part competition (8 Events)
[Car 106 Front Upright]
[Car 106 Rear Upright]
Below
¼” added to the rear
of the upright at top
and bottom to
support brake
bracket
Flaws:
Brake Bracket Needed to be ¼”
more toward the outside to
properly line up the caliper
with the brake rotor
Excess Material on Steering
Bracket
Flaws:
Steering Bracket Not Double
Shear
Stepped Brake Bracket Eyesore
and Possible cause for Failure
[Model that was 3D Printed]
Corrections Made After Rapid Prototyping:
-Threaded Hole Size For Brake Bracket
-Height and Depth of Lower A-Arm Recess
-Material Added Between Steering Bracket Tabs
-Bolted Brake Bracket
Advantages of Using Rapid Prototyping
-Fast and Efficient Way of Reinforcing Design Dimensions
-Relatively Cheap to Produce
Brake Bracket
Upper A-Arm Bracket
[Left removable for camber adjustments]
Upper A-Arm Connection
Spec Sheet
Material: 6061 Aluminum
Total Assembly Weight: 2.28 lb.
Total Assembly Volume: 23.85 in3
Weight by Part
Main Upright
1.69 lb.
Brake Bracket
0.44 lb.
Upper A-Arm Bracket 0.12 lb.
Brake Caliper Connection
Spindle Connection
Steering Connection
Lower A-Arm Connection
Main Upright
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Initial Design
◦ Model of current upright
◦ Working design needing optimization
 Reduce weight while maintaining strength
 2.51 lbs
◦ Possible Changes
 Remove Webbing
 Reduce Thickness
 Optimize Material

Al 6061 Alloy decided upon
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First Design
◦ Removal of webbing
◦ Slightly lighter than initial design
 2.46 lbs
◦ Preliminary stress analysis reveal high
factor of safety throughout part
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Second Design
◦ Reduced thickness of part by
0.25”
 Bearing thickness remains the
same
◦ 2.32 lbs
◦ Preliminary stress analysis
revealed high factor of safety
throughout part
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Final Design
◦ Combination of design one and
two
 Thickness reduced to 0.75”
 Webbing removed
◦ Lightest of all designs
 1.64 lbs
◦ Fillet added between feet and
bracing bar to reduce stress
concentration
◦ Resized after prototype test fit
Expected Cost Report
System
Component
Part for
Purchase
Supplier
Main Front
Upright
Aluminum
6061-T6
Brake Bracket
Size
Qty
Price Each
Total Price
Online Metals
2.5” thick
4”x9.75”
2
$92.04
$184.08
Aluminum
6061-T6
Online Metals
.25” thick
12”x12”
1
$28.54
$28.54
Upper A-Arm
Bracket
Aluminum
6061-T6
Online Metals
1.25” thick
2”x1.39”
2
$2.39
$4.78
Rear Upright
Aluminum
6061-T6
Online Metals
2.5” thick
8.5”x9.5”
2
$190.57
$381.14
Total Price
Supplier Part
Number
(without shipping and taxes, including a 10% discount)
= $538.69
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Problem Statement:
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Accomplishments this year:
◦ To design and build an intake that delivers maximum
performance possible for our engine.
◦ Researched different intake styles and chose the most
efficient style
◦ Created and revised design in Solidworks
◦ Ran design through SolidWork’s flow analysis program
◦ Revised our design in accordance to flow results (Still in
progress)
◦ Researched material costs
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Research determined that a spherical collector
upright intake was the most efficient design
(1). The taper of the cone collector should be
between 3-7 degrees
(2). Optimal runner length of 250-325mm
(3). 20 mm FSAE mandated
restrictor
(2)
(3)
(1)
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Typical stock exhaust uses small diameter
crush bent pipe or mandrel bent pipe.
◦ Crush bents are easier and cheaper to make
however reduce the flow by 50%.
◦ To produce the most power exhaust should have
minimal restriction on the exact flow.
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Components: 4 headers and silencer canister
(muffler)
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Goal of runners: Achieve maximum and even
flow to all 4 cylinders
◦ Preliminary design
◦ Revised (Final) Design
◦ Restrictor Version 1
(for 3 degree collector)
◦ Collector Version 1
(3 degree taper)
◦ Collector Version 2
(5 degree taper)
◦ Restrictor Version 2
(for 5 degree collector)
◦
Full Assembly
(3 degree collector)
◦
Full Assembly
(5 degree collector)
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Analysis
◦ Initial Testing using Solidworks FloXpress
◦ Tests one intake runner at a time
◦ Future testing with time dependent modeling
across all four cylinders required for final analysis
System
Component
Air scoop/
Restrictor
Part for
Purchase
Throttle Body
Aluminum
(Body)
*Reuse from
2013 #109 Car
Plenum
Aluminum
Bare Sheet
6061 T6
Al round tube
online
metals.com
.063” thick
2 sq ft
$7.71
$15.42
online
metals.com
online
metals.com
1.375” OD x
.058” wall
.125” thick
6 ft
$31.74
$31.74
1 sq. ft
$14.35
$14.35
TBD
TBD
4
TBD
TBD
Intake Runners
Size
Quantity
Price Each
TBD
Intake Flange
Aluminum
Bare Sheet
6061 T6
Exhaust Header
al round tube
Exhaust
Silencer/muffler
Supplier
*Reuse from
2013 #109 Car
Total Price
TBD
FREE
Total Estimated Cost  $60
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Continue Flow Analysis
Ordering materials
Fabrication
Flowbench testing with fabricated intake to
verify analysis results
Design of the exhaust once more
components of the frame are assembled