Background Info
● VMS started as a Senior Capstone in 2001● A Student run group with Internal Combustion
and Electric Race cars● VMS has been competing at Lincoln Nebraska
for the past 6 years, with a highest placing of 16th in 2012
● Over 100 Universities around the world compete in our competition
Current Exhaust Status
● Nearly failed dynamic sound tech● Long installation times of muffler and header ● Muffler is nearly 4 years old● Muffler is bulky and heavy
Project Organization
Two-part based project:1. Header 2. Muffler Design
Four subsections for execution1. Design2. Manufacturing3. Test4. Validate
Gantt Chart
Research
External:● Formula SAE documents● Engine Design textbooks● Peer review articles● Performance car websites
Internal:● Previous Experience● Previous Designs/Documents● Fluid-Thermal Dynamics
[2]
Header: Design Requirements
● Optimize flow and power: prefered RPMs 6,000 - 10,000
● Decrease weight: target less than 50% of current model (12 lbs. 6 lbs.)
● Increase packing efficiency: tight package● Maximize ease of installation
Header: Concept Evaluation
What to down select?
Muffler: Current Design
12 lbs
13”
Muffler: Design Requirements
● Lightweight● Similar size or preferably smaller package● Passes sound test● limit restriction and turbulence ● Repackable● Meet FSAE Rules
Muffler: Concept Evaluation
● Absorptive vs. Reflective● Lightweight● Repackable...
Perforated cylinder
Packing Material
Muffler: Concept Evaluation
Fiberglass
Stainless Wool
Sintered Metals
Header: Detail Design
Oil Filter
Muffler: Detail Design
23.6”17.7”
Axle Must be shielded
Packaging
Materials and Manufacturing: Detail Design
Stainless Steel
Mild Steel
Aluminum
Titanium
Carbon Fiber
Muffler: Testing
19.68”
Idle: 100 db
All other speeds: 110 db
Testing
Dyno-testing
Documentation
● Binder of overall info
● Poster with critical design details
● Online cloud storage
● VMS Wiki
References
1. McFarland, Jim 2006: Header Basics - How Headers Contribute to Horsepower http://www.hotrod.com/how-to/engine/header-basics/
2. Blair, Gordon P. Design and Simulation of Four-stroke Engines. Warrendale, PA: Society of Automotive Engineers, 1999. Print.
3. Gos, Zenden. "4-1 vs 4-2-1 Header(Extractor)." 4-1 vs 4-2-1 Header(Extractor). 2012. Web. 30 Jan. 2016.
4. "Spiral Arts." Spiral Arts. Web. 30 Jan. 2016.5. Kane, Jack. "- Exhaust System Technology-." Exhaust System Technology: Science and
Implementation of High Performance Exhaust Systems. RACE ENGINE TECHNOLOGY MAGAZINE. Web. 30 Jan. 2016. Modified Version
6. “Are We Ready To Weld Yet? - Part 5” Burns Stainless. Web. 30 Jan. 2016.
Questions?
WAAZZUUPP!