Why are we here?
The main issue we are here to solve is to design an exhaust system that best optimizes the performance for a student-built formula car. The means of which we plan to do this revolves around revising and improving mixed exhaust components that were designed/fabricated for a competition car used in previous years. Ideally we would take high functioning components and integrate these to make a highly efficient formula exhaust system.
Our motivation behind designing this system is attributed to the exhaust’s contribution to the engine’s racing performance, more specifically, the breathability of the engine. Our end goal is to build a car that not only passes the initial inspection, but also achieves a high ranking position for the May 2024 competition. To do so, we are focusing on limiting the amount of harmful back pressure in the system and performing studies to see how much scavenging we can integrate with our design, to help with its functionality
We believe that our proposed solution will bring us to a stable starting point without cutting down on our expenses drastically. With this solution we would also be getting experimental data early in the design phase since most of the components we would be using are in good conditions, which can be an be a big plus for us over using fluid dynamics simulations because we get a better sense of how the exhaust gasses will flow out of the engine in the real world.
What needs to be done?
The main goal is to design an exhaust system that can guarantee the expelling of the waste gasses generated during the combustion of air and fuel of an engine such that the performance of the engine is optimized. This being said, the exhaust would have to minimize the backpressure to avoid flow restrictions of the exhaust gasses coming out of the engine (process of replacing the exhaust gas in a cylinder of an internal combustion engine with the fresh air/fuel mixture for the next cycle). Moreover, the exhaust design will be based on desired scavenging performances that can be determined through pressure gauge readings and CFD for a more gradual combustion cycle. One focus of the design would be noise control. Average car exhausts are designed to emit between 70 and 85 decibels, our goal is to fall in the range between 80 and 100 decibels, achieving this by designing a muffler that is able to maximize the cancellation of sound waves emitted by the engine. Our constraint is to remain 103 dB at idle or 110 dB at all other speeds. Additionally, the heat that is transmitted into the metal components that may come into contact with the driver needs to be maintained under 60 degrees Celsius as outlined by FSAE rules
What are some challenges we must face?
One of the difficulties the design process would introduce is safety concerns, would the design also have to take into account emissions, more specifically should there be a filter that ensures there are not large quantities of carbon dioxide being emitted. Another issue would be ensuring the integration of the exhaust system into the overall car’s assembly is safe and that it does not affect the rules or performance of any other subsystem the engine needs. Material and manufacturing access is another challenge we will face when fabricating our prototype. In addition to this, as stated before, we will be collaborating with different teams, this could bring unexpected challenges when working together to complete our main goal.
2009 Yamaha FZ-6R engine assembly placed on stands for further inspection of the engine’s quality, and ease of accessibility to test the exhaust components’ performance
Final fabrication stages of an exhaust manifold which was designed by UH FSAE in previous years, our challenge here is to verify the compatibility of this component to the rest of the system
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