A little FSAE Fabrication I did.

[Filthydubber]

Hey guys. I finally found some time to post some progress of fabrication I've done on the forumla SAE car for school.

Let me know what you think.

Intake manifold fab.








And with the diffuser on.



Exhaust fab.


Ut oh, 1 and 3 were not the same length!



Do it again. This time better. Much better


The header fit up was finished as of yesterday afternoon, but I didn't get a shot of it together. Final welding on has started.

Thanks for looking, Ill post more as I continue to work through the exhaust, finish the intake, and finish up the frame.

[leebro61]

Are you doing the design work, or just the fabrication?

[Filthydubber]

Are you doing the design work, or just the fabrication?

Both, and that's the beauty of it.

[leebro61]

Are you open to suggestions for improvement?

[Filthydubber]

of course!

[leebro61]

of course!

Awesome, some people post these threads only looking for a pat on the back, and don't take suggestions very well

First, I think it's great that you're getting a chance to do all of this stuff. I did a little bit with the FSAE guys when I was in school, but I commuted a long distance to campus, so I didn't get heavily involved. Most of my involvement was bringing my own personal projects into the shop and using their flow bench

I'm headed to lunch right now, but I think the biggest room for improvement here is the intake plenum. I think you would want to get rid of the inlet pipe dumping directly into the plenum and try to add a transistion there, since it looks like you've got a bit more room to work with. If you leave it as is, you're going to create a shear layer and you're going to bias your flow distribution toward the middle runners, and you're going to take a pressure loss associated with the flow separation. On the exhaust side, the only thing I can see is that you had to "cheat" a few of the bends. I don't know if this was intentional, but I do know it's usually pretty hard to cut bends exactly on the tangency point without some pretty cool fixtures.

Are you using any software to quantitatively evaluate your design?

[Filthydubber]

Awesome, some people post these threads only looking for a pat on the back, and don't take suggestions very well

First, I think it's great that you're getting a chance to do all of this stuff. I did a little bit with the FSAE guys when I was in school, but I commuted a long distance to campus, so I didn't get heavily involved. Most of my involvement was bringing my own personal projects into the shop and using their flow bench

I'm headed to lunch right now, but I think the biggest room for improvement here is the intake plenum. I think you would want to get rid of the inlet pipe dumping directly into the plenum and try to add a transistion there, since it looks like you've got a bit more room to work with. If you leave it as is, you're going to create a shear layer and you're going to bias your flow distribution toward the middle runners, and you're going to take a pressure loss associated with the flow separation. On the exhaust side, the only thing I can see is that you had to "cheat" a few of the bends. I don't know if this was intentional, but I do know it's usually pretty hard to cut bends exactly on the tangency point without some pretty cool fixtures.

Are you using any software to quantitatively evaluate your design?

Yup the intake was designed in StarCCM, and running it through the model, there didn't seem to be any flow separation. Ill take a look back at it tonight and verify that.

And for the exhaust: Welp, I pretty much got thrown into that one, since no one took it apon themselves to design it. So it was pretty much a last minute thing (even though it shouldn't have been). All of the cuts were eyeballed in a horizontal bandsaw, and some of them had to be cheated in order to bring a pipe into the proper place.

Unfortunately it isn't the best way to do it but it had to be done on a few sections. This is my first year in FSAE and this is the teams 4th car. All I was working towards was an improvement of the exhaust over last years, not the best one. At least they are equal length this year.

I'll snap a picture of last years setup, and you can tell me what you think.

[leebro61]

Yup the intake was designed in StarCCM, and running it through the model, there didn't seem to be any flow separation. Ill take a look back at it tonight and verify that.

And for the exhaust: Welp, I pretty much got thrown into that one, since no one took it apon themselves to design it. So it was pretty much a last minute thing (even though it shouldn't have been). All of the cuts were eyeballed in a horizontal bandsaw, and some of them had to be cheated in order to bring a pipe into the proper place.

Unfortunately it isn't the best way to do it but it had to be done on a few sections. This is my first year in FSAE and this is the teams 4th car. All I was working towards was an improvement of the exhaust over last years, not the best one. At least they are equal length this year.

I'll snap a picture of last years setup, and you can tell me what you think.

I'm not familiar with StarCCM, but I run a lot of CFD and even write a bit of code myself. I think if you're not seeing separation it's most likely because of the way you're post processing the case or because of the boundary conditions you're applying.

I think you did good work, and it's certainly a good experience to design parts and then go actually build them. An experience that not a lot of engineers actually have...

[vr-vagman]

Hi, I can't really give any advice to you but here is something to consider:

[jettred3]

good work.

[Filthydubber]

good work.

thanks,

sorry leebro, I didn't get back to you, I've been super busy and haven't run the simulation.

Last time I did, the flow did tend to be towards the center cylinders, but that was done setting all the valves open at once. You have to remember that since not all the valves are open at once and the flow is highly turbulent, the inlet position isn't going to make much of a difference.

[fourmotioneer]

Which car was this for? Looks good. My guess is the York College car, but it looks like you're in CT.

I did the header on the the Rose-Hulman car this year. My buddy did the intake and sent it to Realize Inc to get rapid prototyped.

[Filthydubber]

Which car was this for? Looks good. My guess is the York College car, but it looks like you're in CT.

I did the header on the the Rose-Hulman car this year. My buddy did the intake and sent it to Realize Inc to get rapid prototyped.

I did this for University of Connecticut car.