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Current System
●Barely passed noise test – 110 dB limit●Header is not optimally designed – Unequal ●Muffler is simply too old
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Project Overview/Goals
●New exhaust system optimized for noise/performance balance
●New system reduces weight ●Meets FSAE Requirements
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Header: Design Requirements
● Optimize flow and power: prefered RPMs 6,000 - 10,000
● Increase packing efficiency: tight package● Maximize ease of installation
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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
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Our Progress
Two-part project:1. Header 2. Muffler
For each stage:1. Design2. Manufacture3. Testing/Validation
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Gantt Chart
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Header Design
Length to: 1st Collector ≈ 20in. 2nd Collector ≈ 10in.Material: 304 Stainless SteelAcquired: Columbia River Mandrel Bending
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CUTTING JIG
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WELDING JIG
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WELDING JIG
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Sugaring Effects
Solution: Purging
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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]
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Aluminum Muffler Box
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STAINLESS STEEL MUFFLER BOX
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CARBON FIBER MUFFLER BOX
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CARBON FIBER PREP
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CARBON FIBER PREP
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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]
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BAFFLE SELECTION
Two Stage AbsorptiveMaterial: Mild SteelPacking Material: SS WoolAnd Fiber GlassMajor Diameter: 2.25 inTotal Length: 28 in
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BAFFLE PRODUCTION
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FINAL LOOK! (Sort Of)
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The home stretch…..
● Fabrication deadline: May 20th, 2016● Prototype Test Date: May 28th, 2016● Data Evaluation● Final Modifications● Documentation● FINAL PRESENTATION: June 2nd, 2016
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QUESTIONS?