Current System

●Barely passed noise test – 110 dB limit●Header is not optimally designed – Unequal ●Muffler is simply too old

Project Overview/Goals

●New exhaust system optimized for noise/performance balance

●New system reduces weight ●Meets FSAE Requirements

Header: Design Requirements

● Optimize flow and power: prefered RPMs 6,000 - 10,000

● Increase packing efficiency: tight package● Maximize ease of installation

Muffler: Design Requirements

● Lightweight: target less than 50% of current model (12 lbs. 6 lbs.)

● Similar size or preferably smaller package● Passes sound test● Limit restriction and turbulence ● Repackable● Meet FSAE Rules

Our Progress

Two-part project:1. Header 2. Muffler

For each stage:1. Design2. Manufacture3. Testing/Validation

Gantt Chart

Header Design

Length to: 1st Collector ≈ 20in. 2nd Collector ≈ 10in.Material: 304 Stainless SteelAcquired: Columbia River Mandrel Bending

CUTTING JIG

WELDING JIG

WELDING JIG

Sugaring Effects

Solution: Purging

HOUSING CONSIDERATIONS

•Aluminum Box • Mid to lightweight• High thermal conductivity• Issues mating to steel baffles and headers

•Carbon Fiber Box•Lightest option•High specific strength•Cannot be operated over 300℉

•Stainless Steel Box•Homogenous material •Adds unnecessary weight•Shortened total baffle length (24”)

[2]

Aluminum Muffler Box

STAINLESS STEEL MUFFLER BOX

CARBON FIBER MUFFLER BOX

CARBON FIBER PREP

CARBON FIBER PREP

BAFFLE CONSIDERATIONS

•Absorptive • Free flowing, less backpressure• Eliminates a range of noise

•Reflective•Greater Sound deadening•Not free flowing

•Double Tuned Helmholtz•Specified sound attenuation•Redundant design with Helmholtz chamber

[2]

BAFFLE SELECTION

Two Stage AbsorptiveMaterial: Mild SteelPacking Material: SS WoolAnd Fiber GlassMajor Diameter: 2.25 inTotal Length: 28 in

BAFFLE PRODUCTION

FINAL LOOK! (Sort Of)

The home stretch…..

● Fabrication deadline: May 20th, 2016● Prototype Test Date: May 28th, 2016● Data Evaluation● Final Modifications● Documentation● FINAL PRESENTATION: June 2nd, 2016

QUESTIONS?