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.
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.
https://cornerstone.lib.mnsu.edu/urs/2014/oral_session_12/3
