2011fall-T1-TurboExhaustManifold

2011fall-T1-TurboExhaustManifold - EML 4905 Senior Design...

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EML 4905 Senior Design Project A B.S. THESIS PREPARED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING HIGH PERFORMANCE TURBO EXHAUST MANIFOLD Final Report Elmer Gutierrez Michael Martinez Rogelio Muro Advisor: Professor Andres Tremante November 16, 2011 This B.S. thesis is written in partial fulfillment of the requirements in EML 4905. The contents represent the opinion of the authors and not the Department of Mechanical and Materials Engineering.
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P a g e | ii Ethics Statement and Signatures The work submitted in this B.S. thesis is solely prepared by a team consisting of ELMER GUTIERREZ, MICHAEL MARTINEZ, and ROGELIO MURO and it is original. Excerpts from others’ work have been clearly identified, their work acknowledged within the text and listed in the list of references. All of the engineering drawings, computer programs, formulations, design work, prototype development and testing reported in this document are also original and prepared by the same team of students. Elmer Gutierrez Michael Martinez Rogelio Muro Dr. Andres Tremante Faculty Advisor
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P a g e | iii Table of Contents Abstract ........................................................................................................................................... 1 Chapter 1 Introduction .................................................................................................................... 2 1.1 Problem Statement .................................................................................................................... 2 1.2 Motivation ................................................................................................................................. 3 1.3 Literature Survey ...................................................................................................................... 6 1.4 Discussion ............................................................................................................................... 13 Chapter 2 Project Formulation ................................................................................................... 14 2.1 Overview ................................................................................................................................. 14 2.2 Project Objectives ................................................................................................................... 15 2.3 Constraints and Other Considerations .................................................................................... 15 Chapter 3 Design Alternatives ................................................................................................... 16 3.1 Overview of Conceptual Designs Developed ......................................................................... 16 3.2 Design Alternative 1 ............................................................................................................... 17 3.3 Design Alternative 2 ............................................................................................................... 18 3.4 Design Alternative 3 ............................................................................................................... 19 3.5 Design Alternative 4 ............................................................................................................... 21 3.5 Design Alternative 5 ............................................................................................................... 22 3.6 Feasibility Assessment ............................................................................................................ 23 3.7 Proposed Design ..................................................................................................................... 23 Chapter 4 Project Management ..................................................................................................... 32 4.1 Overview ................................................................................................................................. 32 4.2 Specific Tasks Comprising the Project ................................................................................... 32 4.3 Organization of Work and Timeline ....................................................................................... 33 4.4 Breakdown of Responsibilities among Team Members ......................................................... 34 4.5 Patent/Copyright Application ................................................................................................. 35 4.6 Commercialization of the Final Product ................................................................................. 35 Chapter 5 Engineering Design and Analysis ................................................................................ 36 5.1 Design Based on Static and Fatigue Failure Design Theories: ............................................... 36 5.2 Material selection .................................................................................................................... 36 5.3 Deflection Analysis ................................................................................................................. 49
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P a g e | iv Chapter 6 Prototype Construction ................................................................................................ 54 6.1 Description of Prototype ......................................................................................................... 54 6.2 Prototype Design ..................................................................................................................... 54 6.3 Parts List ................................................................................................................................. 55 6.4 Construction ............................................................................................................................ 55 6.5 Prototype Cost Analysis .......................................................................................................... 68 6.6 Discussion ............................................................................................................................... 70 Chapter 7 Testing and Evaluating ................................................................................................. 72 7.1 Overview ................................................................................................................................. 72 7.2 Design of Experiments - Description of Experiments ............................................................ 72 7.3 Test Results and Data ............................................................................................................ 111 7.4 Improvement of design ......................................................................................................... 129 7.5 Discussion ............................................................................................................................. 130 Chapter 8. Design Considerations ............................................................................................... 131 8.1 Sustainability Report ............................................................................................................. 131 Chapter 9. Conclusion ................................................................................................................. 135 9.1 Conclusion and Discussion ................................................................................................... 135 9.2 Commercialization of the Manifold ...................................................................................... 137 9.3 Future Work .......................................................................................................................... 140 Appendix A, Engineering drawing sheets .................................................................................. 143 Appendix B, Receipts/Invoices ................................................................................................... 145 Appendix C, Pictures .................................................................................................................. 151
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P a g e | v Table of Figures Figure 1 Mazda Miata ..................................................................................................................... 3 Figure 2 After Market Mazda Miata 1.8L Turbo Manifold (Reference 3, OBX Racing) .............. 7 Figure 3 1.8L Turbo Manifold (Reference 4, OBX Racing) .......................................................... 8 Figure 4 Thermal Efficiency vs. Back Pressure(Smith 1) ............................................................ 10 Figure 5 Exhaust Manifold Miata 1.8L ......................................................................................... 17 Figure 6 Exhaust Manifold Miata 1.8L ......................................................................................... 18 Figure 7 Exhaust Manifold Miata 1.8L ......................................................................................... 19 Figure 8 Ram horn manifold configuration .................................................................................. 20 Figure 9 Exhaust Manifold Miata 1.8L
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