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Based on the results obtained in simulations and physical testing, while keeping in mind the manufacturing factors, the 1.7 liter plenum volume with the 6 inch runners configuration was selected, and manufactured out of Ultem 1010.
DID WE MEET OUR GOALS?
Functionality
Final design must be compliant with FSAE competition standards
YES!
The intake system has the 20mm restrictor placed right before the throttle body, which replaced the twin-38mm throttle body that the stock engine has.
A new mounting system was designed so that the intake manifold is rigidly mounted to the engine, replacing the rubber bushings that were there originally.
The system fits within the Tire Surface Envelop of the vehicle, without obstructing other parts nor the driver.
Maximize Performance
Reach at least 80% of stock engine's power with restriction
YES! Actually, it was surpassed!!
Stock engine power = 63.75. hp
Max. power of restricted engine with final design = 60.05 hp
=> Percentage = 94.25% > 80% desired
In addition:
Max.Torque = 42.70 ft.lb @ 7000 rpm
This parameters will help the Panther Motorsports have a better execution at competition, as the engine is delivering more power and torque.
Durability
System should survive on-track test and competition
YES!
The material selected, Ultem 1010 offered high mechanical strength, impact resistance and a glass transition temperature above the working temperature of the engine.
After each physical testing, the system was monitored to ensure no visible damage was experienced after multiple runs. There were approximately 40 dyno runs and 20 acceleration runs, and no damage was observed. Thus with the material selected the team should be able to utilize the intake system even after this year's competition, achieving the goal. In conclusion, the system fully satisfied all pre-established goals and consequently demonstrated to be suitable for its application with satisfying all needs.
A summary of the results obtained for this intake are listed below:
Restrictor was implemented, reducing the cross sectional area of the inlet to about 28% for the stock one.
The image to the right shows the comparison of the cross sectional areas.
Mass flow rate of air at the inlet and outlet was about 0.105kg/s for both. It provides a high volumetric efficiency and consequent increase of power.
Velocity contour showed a cleaner profile, with less turbulence slowing down the flow, and a much cleaner path to the outlet compared to other plenums especially adjacent to the plenum wall on the outlet side.
In addition, the smallest geometry results in a more convenient manufacturing.
Based on dyno testing, that designed (blue line) provided 60.05 hp at 8220 rpm, while the unrestricted one provided 63.71 hp at 8220 rpm, which gave a total of 94.26% of the entire stock engine power which is above the pre-established goal of at least 80%.
To put in perspective, we were 5.74% off from achieving the same power as the stock engine, with only 28% of the cross sectional area for the air to flow into the cylinders.
The maximum torque was 42.70 ft.lb at 7000 rpm.
After multiple runs for mock competition events, with different drivers. The 1.7 liters intake was chosen based on driver feedback on throttle response, and peak power experienced at higher rpm.
WhatsApp Video 2022-04-25 at 2.26.09 PM.mp4The system was rigidly mounted using v-band clamps to the injector housing , which was bolted onto the engine via a bracket that was brazed to it. In addition, it lay perfectly within the Tire Surface Envelope.
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