Intake & Exhaust Team James Hogge Rebekah McNally Alisa Phillips Henos Woldegiorgis Upright Team Lloyd Outten Joseph Perry Josh Carroll Taylor Watkins Frame Analysis Team Josh Carroll Lloyd Outten 1

 Design Competition for Collegiate students  Represent ODU’s Engineering Department  8 part competition (8 Events) 2

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[Car 106 Front Upright][Car 106 Rear Upright] 4

 Good Design, but hard to machine. The integrated components would add excess machining time and cost Separated steering and brake brackets. Retains the strength and low weight of original design while lowering machining cost. 5

Brake Caliper Connection Spindle Steering Bracket Lower A-Arm Connection Brake Bracket Upper A-Arm Bracket Main Upright Spec Sheet Material: 6061 Aluminum Total Assembly Weight lb. Total Assembly Volume: in 3 Weight by Part Main Upright 1.42 lb. Brake Bracket 0.44 lb. Upper A-Arm Bracket 0.12 lb. Spindle 0.33 lb. Steering Bracket 0.11 lb. Upper A-Arm Connection 6

Normal Loading Represents Weight of Car at maximum Turning Maximum Von Mises Stress: 46,152,184 N/m^2 Factor of Safety: 5.96 Braking Force Represents Maximum Braking Force Maximum Von Mises Stress: 46,929,128 N/m^2 Factor of Safety: 5.86 Steering Force Represents Maximum Steering Force Maximum Von Mises Stress: 117,611,216 N/m^2 Factor of Safety:

Original Design Midterm Final DesignFinal Design One solid piece Heavy (2.51 lbs) Requires optimization One solid piece Very light (1.64 lbs) Difficult to machine Sharp edges result in multiple stress concentrations Three pieces 1.Upright 2.Two control arm mounts Lighter than original (2.16 lbs) Fewer corners mean fewer stress concentrations Easier to machine

Upright Control Arm Mounts Upright Specs Total Weight: 2.16 lbs Material: Al 6061-T6 Yield Strength: 31,183 psi (215 Mpa) Weight by Part: Upright: 2.02 lbs Mounts: 0.07 lbs e.

Load TransferCorneringFull Simulation Maximum load transfer onto the upright due to acceleration. Max von Mises Stress: 14.3 Mpa ( psi) Factor of Safety: Lateral force on upright due to turning. Max von Mises Stress: 56.1 Mpa ( psi) Factor of Safety: 4.9 Simulation of both the load transfer and lateral force applied to upright due to turning Max von Mises Stress: 57 Mpa ( psi) Factor of Safety: 4.82

 Current Accomplishments:  Researched different intake styles and chose the most efficient style  Created and revised design in SolidWorks  Completed flow analysis  Ordered materials for intake 11

 Intake Research  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 mm  (3). 20 mm FSAE mandated restrictor  Exhaust Research  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.  Components: 4 headers and silencer canister (muffler) (3) (1) (2) 12

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 Analysis o Bernoulli’s equation provides accurate pressure drop calculations o Air Flow velocites obtained by SolidWorks to check for choked flow o Flow rates can be calculated to compare the theoretical volumetric efficiency o Real world Flow Bench testing in the future to determine actual volumetric efficiency 14

 Analysis ◦ FloXpress provides flow through one intake runner at a time ◦ Testing in SolidWorks using the pressure drop calculations ◦ Goal is to verify when restriction chokes engine air flow. ◦ Choked flow only after RPM -Airflow through the intake at 9500 RPM -RPM at which max power was previously recorded -Airflow through the intake at RPM, when choke flow begins 15

Total Estimated Cost  $

-Runners made of pieced together pre- bent mandrel tube -Flanges laser cut by Bauer Compressor of Norfolk -Collector rolled from flat aluminum sheet -Restriction turned from solid aluminum round 17

 Accomplishments ◦ Finite Element Analysis  Patran and Nastran ◦ 5 loading cases ◦ CBAR (1D) Mat. Prop.  4031 Annealed Steel  Various Diameters 18

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20 Factor of Safety: 4.17

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22 Factor of Safety: 4.0

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24 Factor of Safety: 17.6

**Forces from Statically Loaded case also included in this analysis** 25

26 Factor of Safety:.015

**Forces from Statically Loaded case also included in this analysis** **Same Total Force Used from Frontal Impact** 27

28 Factor of Safety:.016

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