Formula SAE (FSAE) Air Intake
Initial Proposal: Proposal PRJ60303 Sem 3 March 18.pdf
Final Report: Final Report Sem 3 March 18 PRJ60303.pdf
- Achieved 1st Runner up for the Engineering Fair of my semester (Semester 3) for March of 2018.
The goal for this project was to design a FSAE air intake optimized for a 2006 Yamaha R6 engine that was used by Taylor's Racing Team. FSAE is a student design competition organized by SAE International that allow engineering students from universities to design and manufacture an open cockpit style race car. FSAE has set rules and regulations to ensure that student participating in the event produce a safe car to reduce injuries and accidents.
Taylor's Racing Team uses a 2006 Yamaha R6 engine for their FSAE car. FSAE requires a new air intake to be designed as a 20mm restrictor is in place for all cars participating in FSAE. An efficient and lightweight air intake would be required to be compliant with the FSAE rules.
TR16 driving at Elite Speedway, Subang Jaya
For this project, the geometry of the air intake as well as the materials that were considered for the air intake were tested to find the most suitable combination. Materials of PLA, steel and aluminum were investigated and aluminum was considered as it was able to withstand higher temperatures.
Designs for Air Intake
When determining the geometry of the air intake, flow simulation was conducted in Solidworks to determine the pressure difference between the entrance and the exit of the air intake. It is important for the air intake to have minimal pressure difference to achieve the highest flow efficiency possible. The packaging of the air intake in the car was also a criteria of consideration during our analysis. As a restrictor is already in place for the powertrain, it is important for the car to have as little drag as possible. An air intake can produce a lot of drag as is it a big structure that is erect above the engine. This is not as big of a concern as the flow of the air intake though as there is often a firewall in front of the air intake, reducing the effect of drag produced by the design of the air intake.
Flow Simulation of Air Intake Conducted in Solidworks Flow Simulation
In the end, with all the data analysis as well as the design considerations, the project concluded with the material of aluminium and the design of a conical air intake will be best suited to be produced as the air intake for the engine. This design was chosen as the conical design allows for smooth air flow in the plenum while having the benefit of reduced footprint inside the powertrain compartment. The design has sheet material manufacturing in mind, with flanges placed strategically to allow for easy fastening and disassembly of the air intake when needed.
Design of Air Intake Chosen to be used
