Event Title

Formula SAE Composite Intake System

Location

CSU 204

Start Date

21-4-2014 2:10 PM

End Date

21-4-2014 3:10 PM

Student's Major

Automotive and Manufacturing Engineering Technology

Student's College

Science, Engineering and Technology

Mentor's Name

Bruce Jones

Mentor's Email Address

bruce.jones@mnsu.edu

Mentor's Department

Automotive and Manufacturing Engineering Technology

Mentor's College

Science, Engineering and Technology

Second Mentor's Name

Gary Mead

Second Mentor's Email Address

gary.mead@mnsu.edu

Second Mentor's Department

Automotive and Manufacturing Engineering Technology

Second Mentor's College

Science, Engineering and Technology

Description

The reasoning for this research is to investigate the best method for manufacturing a composite intake plenum for use in the Formula SAE competition. The competition is a performance-based event, so it is critical that the engine makes as much horsepower as possible. So the intake must have high performance characterizes. The goals for the intake were to flow 120 CFM, have high manufacture quality meaning that it had no air leaks or imperfections after being made, and have as high of air velocity as possible for good fuel atomization while still meeting the first goal of airflow above 120 CFM. In order to meet this goal various manufacturing methods were researched and the results of their success from other teams was analyzed. Research was also done in order to determine the proper size of our plenum that would yield the best performance for our engine. The first method that was tried was using a foam core to manufacture our part around. This method had a lower cost and a quicker manufacture time than other methods explored, but the ability to lay composite fiber around the 3D shape proved difficult and did not give us the sealing or air flow goals we had set out for. The next method that was explored was using a plastic mold of only half the plenum, and then making two halves to combine into a finished product. This method had much better results and met the goals we set out to achieve.

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Apr 21st, 2:10 PM Apr 21st, 3:10 PM

Formula SAE Composite Intake System

CSU 204

The reasoning for this research is to investigate the best method for manufacturing a composite intake plenum for use in the Formula SAE competition. The competition is a performance-based event, so it is critical that the engine makes as much horsepower as possible. So the intake must have high performance characterizes. The goals for the intake were to flow 120 CFM, have high manufacture quality meaning that it had no air leaks or imperfections after being made, and have as high of air velocity as possible for good fuel atomization while still meeting the first goal of airflow above 120 CFM. In order to meet this goal various manufacturing methods were researched and the results of their success from other teams was analyzed. Research was also done in order to determine the proper size of our plenum that would yield the best performance for our engine. The first method that was tried was using a foam core to manufacture our part around. This method had a lower cost and a quicker manufacture time than other methods explored, but the ability to lay composite fiber around the 3D shape proved difficult and did not give us the sealing or air flow goals we had set out for. The next method that was explored was using a plastic mold of only half the plenum, and then making two halves to combine into a finished product. This method had much better results and met the goals we set out to achieve.

Recommended Citation

Lutz, Thomas and Garrett Luce. "Formula SAE Composite Intake System." Undergraduate Research Symposium, Mankato, MN, April 21, 2014.
http://cornerstone.lib.mnsu.edu/urs/2014/oral_session_12/3