C.L.I.P. Printed FSAE Performance Intake Manifold
imgur.com/a/nIB2d
imgur.comPosted Mar 30, 2017, 3:32 PM UTC
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imgur.comIt's pretty cool that they can print a gasket into the flange, but what kind of durability does it have? If the gasket wears out, you need to replace the whole thing? Or just put on a traditional gasket at that point?
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The lower portion of the assembly consists of two separate prints. They were then fused together in post-processing. I believe the gasket was printed separately out of their Elastomeric PolyUrethane (EPU) resin. The vehicle won't be in service for much outside of the competition so its not likely that we'll need a replacement.
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Ah ok, so the gasket can just be replaced like any old gasket. It looked like it might have been fused to the assembly.
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Ah, no. It's removable.
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What's the Tg on that material?
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Tg?
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Glass transition temperature
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Not sure, but I will ask.
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Data sheets can be found here: http://www.carbon3d.com/materials/rpu-rigid-polyurethane/
I'm not seeing Tg, but the heat deflection temperature seems low for engine components.
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That looks excellent, can't wait to see it in person!
-SDSU EV
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Thank you. See you in Lincoln!
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Awesome! Looks like this is at sac state? I'm a master mechanic and fabricator in Sacramento currently back in school for mechanical engineering at the community college and I'm extremely excited for FSAE at whatever university I end up at!
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Sure is Sac State. FSAE is a solid investment.
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How does it compare strengthwise?
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We will be testing in the next couple of months.
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Let me know!
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Coupon, component, or full article? Thermal included?
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Is your CFD for the intake assuming steady-state flow, or have you looked at harmonics?
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The CFD only involed steady-state flow, as my knowledge of modeling transient flow in Solidworks is next to nothing. I ran numerous simulations with each runner individually, and also as if all 4 cylinders were pulling air at once, all at different imposed velocities and pressures. Before this intake design, I designed several others based on harmonics, but came to this design due to spacial constraints and other things with the design of the car this year.
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Really cool! How tough is FSAE? worth enrolling for a senior design course? I got yeeeeaarsss a head of me - still haven't taken differential equations
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How on earth did that aluminum part take 4-5 hours on a CNC??
Cool to see the new part though, what was the weight savings compared to the traditional manifold?
They are students, so double the time required for programming/fixturing/set up work. Then consider that they probably have something with the horsepower/speed of a bridgeport knee mill rather than a fully enclosed CNC that professional shops have and you could get there pretty easily.
Very accurate. We only have one fully enclosed CNC so we have to prioritize what parts get made on which machines.
That time includes squaring up the block, machine prep, and all the other little necessities that people overlook. Actual machining of that part only takes 1-2 hours.