Hello!
Thought I´d share this project I am working on. It started with me wanting to get better at 3d-modelling and to try and use the tools I have learned so far. I am currently on my last year of MSc mechanical engineering studies so I am lucky to have access to several different laboratories to do the work

Also this thread has been inspiring me to realise this project:
http://forums.hybridz.org/topic/6154...intake-plenum/


I have been doing the engine package design for our universitys Formula Student-team for a couple of years and so I have made a complete model of the YB engine in an engine simulation software called GT-Suite. All dimensions such as runner length, runner area, plenum volume etc have been calculated through this software and implemented in the 3d-model.



To verify functionality I have done finite element analysis of the complete structure as well as CFD simulations.

The boundary conditions on this simulation was wrong, the inlet velocity shown is over 110m/s, as opposed to 50m/s in reality. I have done more accurate simulations, but I do not have any picture of it. Might do the simulation again and upload some better results



Swirl / turbulens at 2 and 3 as a result of too high inlet velocity

Did a quick video showing steady state result:




Some pic of the model. They are a bit random as I have been working on this for the last 6 months, designing and re-designing.. Ended up with a MIS / Jenvey hybrid design.

I will do some new renderings soon. It is actually only partly complete in these pictures












The velocity stacks will be made out of carbon fiber in a small autoclave we have down in the fatigue lab. An autoclave is a pressurized and high temp chamber. In combination with pre impregnated (prepreg) carbon fiber cloth one can produce components with perfect shape on both sides:




Fun part begins





















First prototype



4 more times as the first one had some casting inconsistency



Will of course go over these by hand to remove the casting marks etc








I wanted to paint this inlet black so I purchased powder coating equipment. First I tried anodizing the casting, but the high silicon content (7% silicon, the alloy is AlSi7) did not give desired result.

PC equipment;



Failed anodizing on the part seen on the left (first prototype used for testing. should have turned out colored black). Also bought seals, bearings, shafts, return springs, throttle plates and complete linkage etc from Jenvey Dynamics. They normally dont sell these parts, but as I am a student they decided to help me out!





The drag angles required for traditional sand casting made the runners hard to fix in a vice during machining, so had to make a simple jig for them. This way I can machine every runner exactly the same way. Im a novice at machining, but trying my best






This last week I have been macnining the molds for the two main plenum covers. The inlet tube will be a Jenvey-style bolt on part, and I have some work left on it before it is ready for machining.
Hopefully I will finish the inlet tube (or whatever you call it) in a couple of weeks














Will be back with more pictures as I machine the parts and sand cast the plenum


Andreas

 

I'll have the finished product to test if you want

 

looks very good. I will be keen to see the finished result.

 

Without doubt the coolest thing I've seen for a while.

 

Stunning work mate to do wot your doing from start to finish is fantastic

 

truly awsome

 

Fantastic!

Looks like fun playing with all the cnc and casting equipment

 

outstanding

 

Thats really cool matey.

 

Fantastic work there pal, must be so satisfying standing back and looking at what you are making.

 

Thank you for your interest! I have been thinking of this project constantly since April, so its very cool finally seeing it taking shape

 

You got skills

 

Wow, thats awesome. Be interesting to see this progress and how the end result performs.

 

Lovely bit of machining there,
I did a smaller scale of 3d CNC machining at my last job, nothing at the extent of this, great work would be good to see the outcome

 

Cool looks interesting

 

Amazing skills. Fancy doing a zetec turbo one?

 

If this was my full time job no problem. The amount of work required from start to finish is ridiculous hehe. I hardly pay attention at school anymore

 

Shame you can't make a few. I reckon you would have orders

 

Lol. If this works out you wont need school. You can sell these the rest of your life

 

Awesome
Price please LOL

 

Thanks mate!

It is a very special feeling seeing the raw castings every time. Suddenly Im holding something Ive made from scratch

Haha I just need my own 3 axis CNC

 

great work would love to be able to things like that

 

Once you have a mold is the casting expensive ?

 

Extremely impressive mate, makes me wish I'd gone to Uni now.
If you need a test engine mine is available.
Rich

 

Hi, no. Once the molds are ready the sand and casting itself is dirt cheap. Its the pre and post machining that is expensive. Luckily I get all this for free, even the casting material.

Hehe thanks mate
Heres a picture of my testing rig;

 

Fair enough, but you know your steering wheel is on the wrong side lol
Rich

 

Yeah Actually I will have to modify the PAS reservoir as the new inlet will collide

Also currently modifying the standard pedal box as I want more adjustment on the hydraulic clutch. Going to be mounting the master cylinder inside of the car rather than on the bulk head as it is now. Im not able to move it around for adjustment, as place is too tight !

 

Great Skills

Prove the concept, then sell the design

 

awesome work, this is how manifolds should be designed

 

Can you post or pm me pictures of the pedal box modification. My car is LHD also and I would like to convert to hydraulic clutch but worried about room for the master cylinder.

 

fantastic

 

Excellent work.. Look forward to seeing more pictures

 

super work there mate, you might have to get theses in to production for some of the guys on here, or is this just a one of?

 

Hi guys, its going slow but managed to do some more work the last month. The runners are now almost completely finished. Just need to machine a hole for the idle screw on one of them, then finish them by hand.

Finished the design on the entry/lower plenum, Jenvey-style
Casting is a bit delayed but hopefully within the next few weeks.

















The runners













Sandblasted (very very find sand used) and finished machining the injector sockets and engine side flange



Made some injector sockets






Thats it for now. Also ordered three lengths of fuel rail stock from RMR. Will have to machine the sockets but at $80 inc shipping waaaay cheaper than finished items at Ł100 each!!

Will only be this prototype for now as it is taking some serious amount of time producing it.

 

AWESOME!!!!!!!!!!!!!!!!!!!!

 

wow!!!!

 

Wow that looks well smart.

 

hat of to you sir! unreal!

 

 

Lovely work....good to see engineering skills like this still being taught....you are the future!