Selection of an engine and design of the fuelling system for a Formula SAE car

Mauger, Travis William (2004) Selection of an engine and design of the fuelling system for a Formula SAE car. [USQ Project]


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This dissertation documents the selection of the engine for Formula SAE car. This dissertation also documents the design and testing of the intake manifold, exhaust system, carburettor and the intake restrictor for the USQ Motorsport Formula SAE engine. Before selecting the engine thorough research into all types of engines and designs was carried out. Once the type of engine that was suitable for the Formula SAE competition was determined, all of the parameters that impacted on the selection of the engine were analysed. To accurately predict which engine was the 'optimum engine' a model of the Formula SAE car's acceleration performance was created and the calculations were undertaken using Matlab. The engine that was purchased for the Formula SAE car was sourced from a 600cc water-cooled motorcycle. Once the engine had been purchased it was possible to design the fuelling system for the Formula SAE car. In this project the fuelling system incorporated the method of aspiration, fuel mixture preparation system, the intake manifold, the intake restrictor and the exhaust system. A feasibility study that encompassed forced air induction systems for the Formula SAE car was carried out and the utilisation of multi-point fuel injection was also examined. However due to budgetary restraints neither of these systems were feasible. Therefore it was decided that the engine would be naturally aspirated and carburetted. The merits of fixed venturi carburettors and constant velocity carburettors were explored in order to select the most suitable type of carburettor for the Formula SAE engine. Research was carried out in order to find the intake manifold configuration that best suited the Formula SAE car. The USQ workshop was also liased with during the initial design period in order to ensure that the machining capabilities at the USQ could produce the required design. In order to determine if the final design of the intake manifold was feasible a prototype manifold was constructed. In order to design the restrictor various standards that are used to design flow measurement devices were incorporated. Several prototype restrictors were constructed and tested using an airflow bench. The design of the exhaust system was also investigated. It was found that the best solution in regards to the exhaust system was to retain the original exhaust manifold and purchase an aftermarket muffler. As the project developed it became clear that cooling requirements of the engine were a concern. For this reason experimental procedures were devised to determine if the original motorcycle radiator would be sufficient. Because all of the components that were designed or specified in this project are part of a system they were tested together, on the engine. Unfortunately it was not possible to obtain any meaningful test results. The reason for this was that the rest of the car was not at a stage of completion that would allow testing on dynamometer. For this reason, at the time of writing, it is uncertain whether the systems that were designed in this project matches the design criteria, which are outlined in chapter 2.

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Item Type: USQ Project
Refereed: No
Item Status: Live Archive
Additional Information: Additional project files available on CD-ROM held in USQ library.
Faculty/School / Institute/Centre: Historic - Faculty of Engineering and Surveying - Department of Mechanical and Mechatronic Engineering (Up to 30 Jun 2013)
Date Deposited: 11 Oct 2007 00:13
Last Modified: 02 Jul 2013 22:30
Uncontrolled Keywords: Formula SAE-A vehicle design, fuel system design, engine design and selection
Fields of Research (2008): 09 Engineering > 0902 Automotive Engineering > 090299 Automotive Engineering not elsewhere classified
09 Engineering > 0902 Automotive Engineering > 090201 Automotive Combustion and Fuel Engineering (incl. Alternative/Renewable Fuels)
Fields of Research (2020): 40 ENGINEERING > 4002 Automotive engineering > 400299 Automotive engineering not elsewhere classified
40 ENGINEERING > 4002 Automotive engineering > 400201 Automotive combustion and fuel engineering

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