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

Media

https://youtu.be/210bpMaR-as

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!