Some of the key physical constraints that must be taken into consideration for our design are the chassis dimensions, the diameters of the exhaust ports on the engine, and our possibilities for custom manufacturing exhaust tubes. More physical constraints are outlined in the table below
We will select acceptable materials for the manifold and midpipe design based on their material properties and heat transfer analysis hand calculations, including the heat convection from the exhaust gasses, conduction of these different materials and radiation from surface of exhaust to surroundings. This will allow us narrow our material selection based on this analysis and available mufflers of different materials
Furthermore, we will be reiterating our initial design based on computational fluid dynamics analysis until we achieve the back pressure/ wave propagation phenomena that we desire for increasing engine performance. By studying how waves propagate along our manifold with different geometrical designs we can select the best option that will give us scavenging behavior, this means using back pressure in advantage by getting more air pulled inside the combustion chamber.
Some physical or soft challenges include:
Having access to the different equipment needed to measure torque, horsepower and revolutions per minute to make sure that we are optimizing engine performance based on the exhaust system design.
Sub teams collaboration and lack of communication because we need to consider all designs based on the surrounding components in the car.
We do not have a fabricated exhaust system from the previous powertrain subteam to gather baseline data points on the performance the exhaust system provided and to be able to compare our prototype data points with. We decided to utilize the stock exhaust system that came with the motorcycle of the engine that we are using. The challenge comes when we notice a piece of the exhaust header port was cut off, so we need to fix this piece to be able to utilize that exhaust system as our baseline data points.
[Figure 1]: This figure represents the 3D design of previous teams that shows one of our constraints with configuration. The red circle is the available space for the exhaust system between the engine and the driver’s seat. The blue highlighted parts represent the driver and were they will be seated.
[Figure 2]: The figure represents the exhaust header port that was broken off and needs to be fixed to look similar to the rest of the ports and fit on the engine exhaust outlet.
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