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Exhaust and Muffler Design of A Formula SAE Car
Exhaust and Muffler Design of A Formula SAE Car
Gajendra Gulgulia 09BEM085 Manu Pant 09BEM031 Mohit Mundra 09BEM033 Project Guide: Prof. Thundil Karupparaj. R Program Manager, Energy Division SMBS, VIT.
LITERATURE REVIEW
KEY POINTS
1. The exhaust system was targeted for maximizing low rpm torque while maintaining a broad flat curve without significant loss of high rpm horsepower. 2. Considerable attention had to be given to the exhaust primary tracts, collector and silencer designs. 3. Effects of modifying the restrictor design, intake runner length, intake camshaft profile, exhaust geometry and silencer design were measured using a transient dynamometer. 4. Optimum design short inlet manifold, long diffuser, reduced valve overlap. 5. Design ,development and testing of a restrictor for use in formula SAE racing.
KEY POINTS
6. Design objectives Increase air flow between a pressure drop of 5 to 15 inches Reduce pressure loss upon plenum entry. Minimize the effects of reversion. Develop a throttle body for minimal flow saperation. 7. A combined analytical CAE procedure and durability experiments are used to calculate the durability of complete exhaust system. 8. Durability issues associated with the exhaust system components such as hot ends bracket, converter cone pipe region ,exhaust pipe system, muffler pipe system, muffler hanger design, and residual stresses in the exhaust system assembly. 9. Aimed at raising engine power and drivability . 10.Ways to get engine power improvement are combustion improvement, the change of the cam profile, and supercharging. 11.Intake air collector and air restrictor redesigned in consideration of installation
KEY POINTS
12.RLDA(Road load data acquisition) is one of the most important steps to verify exhaust system durability performance . 13. First a two degree of freedom system is analyzed; second , 2D and 3D beams sre studied. Then FEA comparison between body side input and exhaust side input are conducted for an exhaust system. 14.At idle engine speed, the exhaust discharge noise is influenced by resonances in the whole system, which is composed of connecting pipes and silencers. 15.The pipe resonance radiates a high level of low frequency discharge noise ,which is dominated by the low order harmonics of the engine firing frequency. 16.This low frequency noise deteriorates the vehicles interior noise level and quality.
Aim of muffler: -To meet packaging constraints -To provide required reduction in noise -To provide minimum back pressure
Types of muffler -Straight through muffler(low B.P, low attenuation) -Resonating Chamber design(Higher B.P, better attenuation) -Reverse Helmholtz resonator
PROJECT DETAILS: A STEP WISE Approach: 1. Design: a. Modelling b. Analysis c. Modification d. Finalization 2. Manufacturing 3. Testing: a. Flow Test b. Dyno Test c. Noise Test 4. Redesign-Repair-Retest(3 R phase) 5. Finalize and conclude
GANTT CHART
Initial Modeling
REFERENCE
PAPER 1.Exhaust system design for a four cylinder Engine- Badih Jawad,Christopher Biggs and Bradley Klein
POINTS DERIVED
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2.Experimental optimisation of manifold and camshaft geometries for a restricted 600cc four cylinder four stroke engine R.H.McKee , G.McCullough,G Cunningham,J.O.Taylor.
3.An experimental approach to design ,build and test a throttle body and restrictor system for formula SAE racing.- Brooke Byam, Jackie Fsadni ,Allen Hart And Rachel Lanczynski 4.Structural durability evaluation of exhaust system components Lakshmikanth Meda, Helge Lawrenz, Martin Romzek. 5.A study on intake and exhaust system of turbocharged engine under the regulations of formula SAE. Syuhei Yamamoto, Shinya Matsumoto, Tomoaki Kodama,Yasuhiro Honda.
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REFERENCE
PAPER
POINTS DERIVED
8.Model transient FEA study to simulate exhaust system road load test-Fulun Yang and 11,12 Henry cheng.
7.Optimal design of the exhaust system layout to suppress the discharge noise from an idling engine.- C-Y choi, T-K SIM,S-H yang
8.The Scientific Design of Exhaust and Intake Systems- Smith and Morrison
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