Year – 2008
Submissions Date - 30/04/08
Formula Student intake manifold design and manufacture for a single cylinder restricted engine 2008 Final Year Project
Supervisor – Geoff Booth
Author – Tom Collyer
School Of Engineering
Formula Student Rules
Software and Hardware Review
Intake Manifold Purpose and Function
Pressure Wave Tuning
Consideration In Reagrds to Formula Student
Previous Formula Student Intake Designs
Intake Manifold Design and Development
Materials and Manufacture
Ricardo WAVE and Floworks Data
Aims and Goals for CFD Analysis
Obtaining Data for CFD
Finalising the Design and Conclusion
For 2008 a new class was introduced for Formula Student. Formula Student is a competition between various universities around the UK and around the globe, organised by the Institute of Mechanical Engineers (IMechE). It allows students to design and build single seater formula styled cars in accordance to rules and guidelines set by the IMechE.
Some universities carry the development of a car over a two year process whereas others (such as ourselves) would be the first academic year to have experienced this. This left us nine months to design and build a vehicle in time for the competition.
The class in which we’ve entered (1A, the newly introduced class), is where vehicles had to run an alternative fuelled engine. Coventry University Motorsport Formula Student team decided to run a bio-ethanol powered vehicle. The rules stated that this vehicle had a maximum engine displacement of 250cc with a “12.3mm restrictor downstream of the throttle” for the intake manifold. Working with such a small restrictor made the intake manifold design crucial to regain the lost power. A development programme was undertaken to improve the performance of the engine (see ?!), the following design was assigned.
The rules allowed for any aspect of the engine to be modified, though it was felt, because the engine was not officially the university’s and it was the first time the university would have experience in running this engine in this format and application, to only modify the intake and exhaust systems.
The intake manifold would also have to be designed and built within a budget. Only a limited set budget is allocated for the formula student team to design and build the vehicle, to which a set amount is set aside for engine development.
The project was to develop and design an intake manifold for a restricted single cylinder engine. This project was met with extensive engine development, combining theory with virtual testing and CFD analysis. This was all met within the engine packaging requirements to design a successful intake manifold.
The project concludes with the production of a series of CAD schematics along with extensive Ricardo WAVE analysis of the final design.
1.3 Formula Student Rules
The IMechE have imposed a set of rules and regulations for a more competitive and equal field of entry and for health and safety reasons. Each...
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