1. VU Motorsports Intake/Exhaust Team
Kristina Kitko
Mark Melasky
Perry Peterson
Tim Wranovix

2. 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

3. 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

4. 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

6. Constraints Described in FSAE rules: Packaging: Cost:
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

8. 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

9. Options Naturally Aspirated Turbocharged Build intake and/or exhaust
Build intake and exhaust

10. 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

11. 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

13. 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

15. Pros Cons 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

16. 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

18. Garrett Turbocharger GT-12 (image on next slide)
Engine horsepower
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

20. Pros Cons 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

21. Next Step Criterion for design decision: Cost Complexity
Design team knowledge
FSAE team input

22. Questions?