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Design and Development of a Dry Sump Lubrication System for a Formula SAE Race Car

VIT University-Rishabh Khanna, Akshyt Bimal Kumar, Kartik Vijaykumar, K Nantha Gopal, Ashok B, Sahil Sharma, Vignesh Ravi
Published 2019-01-09 by SAE International in United States
A Formula student team aims to develop and improve their designs every year, as far as the powertrain aspect is considered performance output and enhancement is the primary aim, and for engine to perform better, the health of the engine is the most important parameter; hence the lubrication system of the vehicles powertrain should be improved to get the most out of the engine. The primary challenge for the development of a new lubrication system was the inability to replicate the performance given by stock wet sump with the self-designed custom dry sump. However, the advantages can outnumber the cons of implementing a custom dry sump lubrication system. The work brought together in this paper highlights the meticulous design procedure for implementing a custom made dry sump system onto a 4-cylinder in-line Honda CBR600RR engine. Moreover, the research paper brings about the extensive process undertaken which includes theoretical calculations, computational analysis and experimental validation of the whole assembly the dry sump system. The design procedure makes use of software like MATLAB, Star CCM+ and SolidWorks.…
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Design and Development of a Restricted Intake Manifold for a Naturally Aspirated Four Cylinder SI Engine

VIT University, Vellore-Aman Agarwal, Umashankar Lath, Saksham Bhardwaj, K Nantha Gopal, Ashok B, Akshyt Bimal Kumar, Rishabh Khanna
Published 2018-07-09 by SAE International in United States
Intake manifold is one of the principal components of the engine system in the vehicle. The air intake manifold is the passage for air into the engine and thus affects the amount of air quantity. The objective of the present work is to design and development of a strong, reliable and light weight intake manifold for a multi cylinder spark ignition engine. The developed manifold will improve the airflow intake and provide equal mass flow rate in all runners to create better performance. In the present work, combinations of 1-D modeling using Ricardo Wave and CFD simulations on Star CCM+ were employed to substantiate the modeling. The designed manifold is ensured to have a throat velocity of the restrictor close of Mach 1and the plenum was simulated to have a zero velocity creating maximum pressure close to atmospheric pressure. The necessary structural strength to the intake manifold was ensured by performing FEA simulations using ANSYS software. Rapid Prototyping Technique was selected to avoid any disruption in the fluid flow and vortex formations among which Selective…
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Design and Development of Cooling System for a Formula SAE Race Car

VIT University-Rishabh Bahuguna, Tanmay Prasad, Rishabh Khanna, Akshyt Bimal Kumar, K Nantha gopal, Sushant Srivastava, Aagosh Mishra, Ashok B
Published 2018-04-03 by SAE International in United States
In Formula Student, the vehicle working parameters are quite disparate from that of a commercially designed vehicle. The inability of teams to incorporate the atypical running conditions in their design causes multiple unforeseen issues. One such condition where the teams fail to improvise upon is the cooling system. Due to the high performance requirement of the competition, multiple teams participating face recurring heating problems. Maximum efficiency from a combustion vehicle can only be achieved when the cooling system is designed to handle the increasing power demand.This paper brings forth a detailed study on the intricate design of the cooling system. The problem has been approached using both theoretical and simulation models. Firstly, NTU-ℇ method was used to calculate the overall heat transfer coefficient and the temperature drop through the radiator core. Various parameters like core size, mass flow rate of water and air, fan configurations etc., were taken into consideration. Star CCM+ software was used to perform full body analysis to study the positioning of the radiator on the race car. Following this, the theoretical…
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