PORTFOLIO
BY
SHIVAM GUPTA
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold
Aims
• To improve engine performance through comprehensive dynamometer testing and on-track testing. To achieve aminimum of 75 bhp.
• To make a reliable and efficient engine system that is aesthetically appealing.
• To reduce overall weight of the different components in the engine subsystem and to make compact system withbetter packaging.
• To make a light weight system that delivers adequate performance.
• To achieve choked flow in restrictor so maximum air is delivered to the engine and ensure minimum turbulence.
• To ensure that each component can be easily manufactured and ensure easy replacement of the given component in case of failure and indigenize parts to lower cost.
• To conduct data acquisition for future use.
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold
Air Filter
Upper & Lower Plenum
Restrictor
Throttle Body
Runners & Fuel System
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold
Air Filter Restrictor
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold (Restrictor)
DESIGN DECISION REASON
Material : Utem, Durfaform
• Easy availability, cheap and good machinability
Basic shape
• Convergent-Divergent type nozzle• Inlet diameter:35mm• Throat Diameter:20mm• Outlet Diameter:56mm• Convergent length:55mm• Divergent Length:175mm
Analysis techniques:• Analysis was conducted in fluent with a
target to achieve maximum static pressure and reduce turbulence.
Manufacturing • Fused Deposition Modeling, 3D Printing
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold
Throttle Body
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold
Lower Plenum Upper Plenum
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold
Upper & Lower Plenum
DESIGN DECISION REASON
Material : Utem, Duraform • The material is selected as it can be readily used for rapid prototyping.
Basic shape
• Log type plenum with tangential entry to conserve momentum.• Plenum Volume of 2.8L increased from 2.4L to reduce starvation.• Flush type bell mouths to reduce formation of vacuum pockets and increase
air flow to engine cylinders.
Analysis techniques• Based on throttle response. In the initial design a throttle change of 10% led to
starvation, so volume was changed so as to avoid starvation and maintain throttle response.
Manufacturing • It will be manufactured by Fused Deposition Modeling.
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold
Runners and Fuel System
FORMULA STUDENT (FSAE)
Design and Analysis of Intake Manifold
Runners and Fuel SystemDESIGN DECISION REASON
Material : Utem, Duraform• The material is selected as
it can be readily used for rapid prototyping
Basic shape
• The intake runners were curved to create a more compact system and to clear the rules for the new chassis.
• The injector housing was integrated into the runners for further space optimization.
Manufacturing• Fused Deposition
Modeling
DESIGN AND FINITE ELEMENTS ANALYSIS (FEA) OF A PLANETARY GEARBOX
• Also known as Epicyclic Gearing
• Three Elements - Sun gear, Planet gear
and Ring gear
• Works on the basis of Gear Ratio
• Compact arrangement and high
transmission efficiencies
Reference - https://s3.amazonaws.com/engrade-myfiles/4083769570221760/40-15.jpg
DESIGN AND FINITE ELEMENTS ANALYSIS (FEA) OF A PLANETARY GEARBOX
Design and Assembly of Components – CATIA using Parametric Equations
𝑥 = 𝑟𝑏 ∗ cosሺ𝑡 ∗ 𝜋 ∗ 1𝑟𝑎𝑑 + sinሺ𝑡 ∗ 𝜋 ∗ 1𝑟𝑎𝑑 ∗ 𝑡 ∗ 𝜋𝑦 = 𝑟𝑏 ∗ sinሺ𝑡 ∗ 𝜋 ∗ 1𝑟𝑎𝑑 − cosሺ𝑡 ∗ 𝜋 ∗ 1𝑟𝑎𝑑 ∗ 𝑡 ∗ 𝜋
TEAM 5
TEAM 5
DESIGN AND FINITE ELEMENTS ANALYSIS (FEA) OF A PLANETARY GEARBOX
Finite Elements Analysis of Components on ANSYS Mechanical
DESIGN AND FINITE ELEMENTS ANALYSIS (FEA) OF A PLANETARY GEARBOX
Finite Elements Analysis of Components on ANSYS Mechanical
MANUFACTURING OF COMPOSITES
Aims
• To Lay carbon-epoxy prepregs on top of the surface of abowl which serves as a mold. The layup is then cured usingan autoclave.
• Modelling of the mold on CATIA & Fiber Simulation onFibersim.
• Manufacturing of Bowl by cutting Prepregs and Hand Lay-Up on mold.
• Curing of Bowl using Autoclave and Vacuum Bagging
• Inspection and Quality check using Macroscopic Analysis and Microstructure Analysis of Results
MANUFACTURING OF COMPOSITES
Optimum Design for 0˚ & 90˚ Orientation of Fiber
MANUFACTURING OF COMPOSITES
Vacuum Bagging and Autoclave
MANUFACTURING OF COMPOSITES
Inspection and Quality Check
0 Degree
90 Degree
0 Degree
90 Degree
THANK YOU
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