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This is a proposal to do research into the combination of a forced induction system into an existing cylinder head for an internal combustion engine for automobile use.
Citation preview
----
------------------- ------------------
- - --------------------- ------ -----
STUDENT GRANT PROGRAM Investigator Information Form
PRINCIPAL INVESTIGATOR
Name Eric Sprague Effort Email spra0272vandalsuidahoedu
VandallD 081-36997 Phone 208-994-1564
Address 231 Lauder Ave Apt B6
Department Mechanical Engineering
Click here to add additional Investigators The combined percent effort of all investigators must total 100
FACULTY SPONSOR
Name Office ------------------- ----------------~
Depa rtment Phone
ELIGIBILITY FOR STUDENT GRANT PROGRAM
[J Undergraduate 0 Graduate D Law [] Full Time Student J Moscow Campus
ARE YOU A FIRST-TIME INVESTIGATOR I Yes No
Have you previously received a grant from this program D Yes f No
If yes have report(s) of previous gra nt(s) been su bm itted D Yes
Proposal Title Forced Induction Cylinder Head
Amount Requested From SGP
Please provide a brief abstract of your proposal (Maximum 200 words)
The goal of this research is to experiment in the combination of a forced induction system directly inside a cylinder head assembly The traditional application of a forced induction system onto an already existing naturally aspirated engine benefits from gains in power output without directly injecting more fuel The cost of installing such a system requires extraneous management of pressurized air coolant and increased loads on the drivetrain [Integrating the two mechanisms together could result in more responsive power reduction in parts cost emiSSions and overall efficiency of
an internal combustion engine This allows for the application of a stronger engine block and crank with a smaller displacement thus providing better fuel efficiency per unit of power output thus Forced induction applications are already standard in commercial road transport vehicles it is time to reduce the cost and increase the availability of a more efficient and cleaner standard to the general market
--------------------------
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- - -- - --- -------
-- -------
-----------------------------------------------------------------------
------------------
RECOMMENDED EXTERNAL REVIEWERS
1 FacultyStaff Name Email
Department
2 Student Name Email
Department ----------------------------------------------~-----------------------
3 Student Name Email
Depa rtment
Project Type C Basic Research [] Applied Research D OutreachService D Instruction
Yes No Click on title for more information Explanation
o Are Human Subjects Involved
Assurance Date
D Are Experimental Animals Involved
Protocol Date
--~------------ ---- - - - - ------~--- ---- -------- _---_- --- shyo Are Biohazards Recombinant DNA or
Radiation Involved Approval Date
n Are Select Agents or High ConsequenceiJ
Livestock Pathogens and Toxins Involved
-=~------- -- Is proposal subject to Export Controls or
Re-Export
o [] o ITAR 0 EAR
------
------
-----
-----
------
-----
-----
--------------------------------
Name Eric SpragueSTUDENT GRANT PROGRAM Project Grant Budget Form Please fill out this form usning Adobe Acrobat Student 10 081-36997
t (t d) for all expenses listed under EquipOlent indicate on page 2 of tl is PDf who will aSSUOle responsibility AmountEqUlpmen I emlze for the equipOlent once the project has been completed
1 Used 4cl Engine or Running 4cl Motorcycle $2000
$000 2
$0003
$0004
$0005
Materials and Supplies (itemized)
1 Aluminum Stock
2 Miscellaneous Parts
3 Tooling materials
4
5
Equipment total _$_20_0_0___
$300
$700
$100
$000
$000
Travet Costs (itemized)
1 List items Here
2
3
4
5
Materials and supplies total _$_1_00_0___
$000
$000
$000
$000
$000
Travel total $000----shyPersonnelServices (itemized)
1 Master Machinist Assistance $1600
2 $000
3 $000
4 $000
5 $000
Personnelservices total _$_0_0_0___ Other Expenses (itemized) All items listed under Other Expenses must be accompanied by a justification statement on the 2 page of this PDf
1 List Items Here $0 00
2 $0 00
3 $0 00
~ WOO -----
5 $000 ------
6 $000
7 $000
Other total $000
Subtotal $4600
Facilities and Administrative Costs (800) _$_36_8___
Your Current Total $000
Total must NOT EXCEED $500000 Total Request _$4_9_68__
----------------------------
11
Justification - For all expenses over $100 and those items listed under Other Expenses describe the expenses such
that reviewers and committee members will be able to immediately recognize the relevance and necessity of the items
For all expenses listed under Equipment indicate who will assume responsibility for the equipment once the project
has been completed
Equipment (itemized)
Number Who will assume responsibility for the equipment once the project has been completed
iThe Master Machinist of the University of Idaho
Justification for expense if over $100
As the prototype is a component of the engine assembly a strong four cylinder engine is required to model the application of multiple cylinders The unit must also be able to withstand higher power outputs
Number
I Justification for expense if over $100
Who will assume responsibility for the equipment once the project has been completed
Number Who will assume responsibility for the equipment once the project has been completed
I
Number Who will assume responsibility for the equipment once the project has been completed
Justification for expense if over $100 --------------------------------------------------~
Number
Justification for expense if over $100 ----------------------------------------------------~
I
PersonnelServices (itemized) For all expenses over $100
Number Justification for expense
rThe Master Machinist Russ Porter is an invaluable resource He is constantly giving insi~t-to better ] II ~c~chining through economy and ingenuity Whatever the University pays him its not enough The ~imates are based on above average machinist pay at about 80 hours of contribution
----------------
Number ~stificatio n fo~ expense-______________ --_
Number Justification for expense
I Justification for expe se n~_______________________________Number
Number Justification for ex ense _~~____- ___---___-~________________
Other Expenses (itemized) Number
Number
~P I
~-------~= ~====~========================~=============== Nmh [ bOO fo poc l ----- ----- ============================= Number
Number Justification for expense
I Number Justification for expense
Number Justification for expense
-l
Cover Letter
The main purpose of this research is to decrease the cost of implementing a cleaner and more efficient standard in the construction of an automobile engine Forced induction is a process in which air is forced into an engine at above atmospheric pressure creating a better environment for the fuel to burn The most obvious benefits are the increases in power output and the decrease in emissions The reason however that these methods are not more commonly applied in standard consumer vehicles is the increased cost
The benefits of adding forced induction are already well known and have been implemented in commercial engines since 1938 Most of the research already conducted shows significant gains in power and emissions Complications are derived from handling the added power and heat Two common applications of forced induction are the Turbocharger and the supercharger one running off of exhaust fumes and the other off of the rotation of the engine For this purpose using the supercharger model for integration appears to be simpler to apply in the space constraints of a cylinder head
By integrating the forced induction unit into the cylinder head the goal is to simplify the overall system to the most essential components and close the distances included in traditional applications The reduction of parts lowers costs and the shorter operating distances reduces extraneous stresses on components along with decreasing the space needed for the system to occupy By minimizing the amount of highly pressurized air sections of the system there will be less excess heat being generated to decrease the power output
The automotive industry is always looking for more ways to increase efficiency and lower emissions whether it is from competition or by government regulation The University of Idaho already has many resources dedicated to high efficiency vehicle research leaving not much left to buy outside materials needed to build a functional prototype and a used engine to be tested on Such a prototype can be easily patented and marketed by the University to companies to be licensed out
The main requirements are could best be envisioned as a inline-four-cylinder engine on a working motorcycle chassis A complete system motorcycle system would come with all the fuel ignition and extraneous parts needed for testing The university already has computer aided design programs for designing considerable machining capacity and testing facilities for the full prototype process to be maintained completely in-house Other substantial expenses would be derived from bearings geais and other miscellaneous parts
My own personal passion for automobiles and desire to work in said industry leads me to believe this endeavor will positively impact my career as a mechanical engineer as well as the universitys reputation as a leader in innovation
Narrative
Objectives
Reduce the number of parts
By using the cylinder head as the main mount for the whole assembly general parts
from a supercharger can be integrated into head 5uch items as the corkscrew or other pressure
increasing turbine blade can be mated right at the entrance of each induction port To power
the spinning blades a gear assembly can be ran directly off the camshaft Lubricant and cooling
that already runs through the head can be redirected within the head assembly to reduce the
burden on pumps
Reduce power losses from heat
A major consideration when upgrading a naturally aspirated to forced induction in
managing the heat created by pressurizing air (52) As a higher intake temperature in the air
results in power losses the introduction of intercoolers is used to cool the air down before it
enters the engine By minimizing the distance traveled by the pressurized air the amount of air
that is pressurized at a moment in time can also be minimized and less pressurized air moving
to the engine will reduce the amount of heat generated and therefore minimize power loss in
that area
Lower Emissions
When the gas enters the combustion chamber at a higher than atmospheric pressure
there are more oxygen molecules per unit of air to contribute to the combustion of the fuel
This allows for the more efficient burning of the fuel leaving less undesirable molecules such as
carbon monoxide With less fuel being burned per unit of power obtained a car fitted with this
application can lower its carbon dioxide emissions without compromising on the desired power
output With ever increasing demands on emissions by the government developments in
cheaper ways to lower emissions on current petroleum driven engines is sure to be in demand
Room for future development
This development can be seen as a stepping stone to future developments in the
continuous improvements of internal combustion engines Once power gains have been
established with forced induction applications the lower engine block can begin to be resized
for the proper displacement along with compensation for the higher power demands of the
lower engine components
Importance
Improved Power Output amp Lower Cost
Horsepower ratings are a big selling point in the purchasing of an automobile more so
in the United States than other markets So the opportunity of having similar power gains for
less cost than traditional forced induction applications makes this alternative a worthy
consideration
Lower Emissions amp Higher efficiency
With the United States Government constantly trying to reduce greenhouse gasses
created by automobile emissions they are requiring cars to from manufacturers to have an
average mpg rating of 42 or more by 2016 (53) The allure of the same power ratings with less
fuel consumption again makes this a golden opportunity to benefit the whole industry
Minimizing Cons of Forced Induction
The goal of this research is to address the problems created by implementing a forced
induction system Along with lubrication and heating issues addressed earlier there are other
benefits that can result from this system With the lack of distance created by long pressurized
tubes the effective lag in power can hopefully be minimized and the need for a pressure
release valve can be negated all together This will further enforce the benefit of an integrated
system over a traditional one
Methods
CAD Prototype Design
The first phase of the design process is to make a prototype in the three dimensional
environment using computer aided design Using the already existing sophisticated equipment
already owned by the University of Idaho it is possible to use a program such as Catia to model
the prototype Modeling the prototype in this program will allow for the optimization of space
usage in the design Features included in this program such as the Finite Element Analysis tools
will aid in minimizing materials and costs down the road
A generalized model can be obtained via the experimental head unit purchased for the
experiment From there modifications can be added in the 3D program in order to include a
forced induction system Everything from the bearings to the fasteners can be modeled and
accounted for in a final bill of materials
By the iteration process the design would be continuously improved in order to keep it
as simple as possible to machine and assemble The Finite Element Analysis tools can be used to
analyze forces applied to the assembly Other programs such as Genesis can find material that
isnt supporting a load and can therefore be optimized for necessary strength and minimizing
the overall product weight It will also be designed to minimize the number of custom parts
that need to be made in favor for parts available for purchasing The overall goal is to keep
manufacturing costs down and maximize the efficiency of the unit
When the final assembly is complete and ready to be prepped for machining a
complete drawing package can be created for every individual custom part that is to be
manufactured as well as accounting for all the necessary fasteners bearings and other
miscellaneous parts that used for incorporating forced induction
Machining amp Assembly
This section will be the most labor intensive section of the process As much coding is
needed to set up such a relatively complicated part not to mention the time it takes to machine
the parts themselves However the University of Idaho has a CNC Mill that has the capacity for
the machining required While porting and relieving the heads needs a multi-axis mill such
operations can be avoided in favor of editing an existing head unit or making a unit from
scratch to our own capabilities The goal would be to limit machining time to less than 50 hours
of machining
During the assembly phase attention to tolerances is of utmost importance to maintain
the best possible quality and a high life cycle for the unit At this point the cost of miscellaneous
parts comes into play with the correct application of the proper bearings fasteners and other
part sizes This is of course with consideration for part standardization and cost minimization
Testing amp Tuning
This phase will include the optimization of power output and fuel consumption The
facilities available allow us to digitally monitor many aspects of the engine while it is running
By analyzing the collected data the system can be changed accordingly whether it be the
ignition timing compression ratios or valve moment among many other options From the
results we can obtain proper comparisons between the new forced induction system and a
naturally aspirated system
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
--------------------------
-----------------------------------------------------------------------
- - -- - --- -------
-- -------
-----------------------------------------------------------------------
------------------
RECOMMENDED EXTERNAL REVIEWERS
1 FacultyStaff Name Email
Department
2 Student Name Email
Department ----------------------------------------------~-----------------------
3 Student Name Email
Depa rtment
Project Type C Basic Research [] Applied Research D OutreachService D Instruction
Yes No Click on title for more information Explanation
o Are Human Subjects Involved
Assurance Date
D Are Experimental Animals Involved
Protocol Date
--~------------ ---- - - - - ------~--- ---- -------- _---_- --- shyo Are Biohazards Recombinant DNA or
Radiation Involved Approval Date
n Are Select Agents or High ConsequenceiJ
Livestock Pathogens and Toxins Involved
-=~------- -- Is proposal subject to Export Controls or
Re-Export
o [] o ITAR 0 EAR
------
------
-----
-----
------
-----
-----
--------------------------------
Name Eric SpragueSTUDENT GRANT PROGRAM Project Grant Budget Form Please fill out this form usning Adobe Acrobat Student 10 081-36997
t (t d) for all expenses listed under EquipOlent indicate on page 2 of tl is PDf who will aSSUOle responsibility AmountEqUlpmen I emlze for the equipOlent once the project has been completed
1 Used 4cl Engine or Running 4cl Motorcycle $2000
$000 2
$0003
$0004
$0005
Materials and Supplies (itemized)
1 Aluminum Stock
2 Miscellaneous Parts
3 Tooling materials
4
5
Equipment total _$_20_0_0___
$300
$700
$100
$000
$000
Travet Costs (itemized)
1 List items Here
2
3
4
5
Materials and supplies total _$_1_00_0___
$000
$000
$000
$000
$000
Travel total $000----shyPersonnelServices (itemized)
1 Master Machinist Assistance $1600
2 $000
3 $000
4 $000
5 $000
Personnelservices total _$_0_0_0___ Other Expenses (itemized) All items listed under Other Expenses must be accompanied by a justification statement on the 2 page of this PDf
1 List Items Here $0 00
2 $0 00
3 $0 00
~ WOO -----
5 $000 ------
6 $000
7 $000
Other total $000
Subtotal $4600
Facilities and Administrative Costs (800) _$_36_8___
Your Current Total $000
Total must NOT EXCEED $500000 Total Request _$4_9_68__
----------------------------
11
Justification - For all expenses over $100 and those items listed under Other Expenses describe the expenses such
that reviewers and committee members will be able to immediately recognize the relevance and necessity of the items
For all expenses listed under Equipment indicate who will assume responsibility for the equipment once the project
has been completed
Equipment (itemized)
Number Who will assume responsibility for the equipment once the project has been completed
iThe Master Machinist of the University of Idaho
Justification for expense if over $100
As the prototype is a component of the engine assembly a strong four cylinder engine is required to model the application of multiple cylinders The unit must also be able to withstand higher power outputs
Number
I Justification for expense if over $100
Who will assume responsibility for the equipment once the project has been completed
Number Who will assume responsibility for the equipment once the project has been completed
I
Number Who will assume responsibility for the equipment once the project has been completed
Justification for expense if over $100 --------------------------------------------------~
Number
Justification for expense if over $100 ----------------------------------------------------~
I
PersonnelServices (itemized) For all expenses over $100
Number Justification for expense
rThe Master Machinist Russ Porter is an invaluable resource He is constantly giving insi~t-to better ] II ~c~chining through economy and ingenuity Whatever the University pays him its not enough The ~imates are based on above average machinist pay at about 80 hours of contribution
----------------
Number ~stificatio n fo~ expense-______________ --_
Number Justification for expense
I Justification for expe se n~_______________________________Number
Number Justification for ex ense _~~____- ___---___-~________________
Other Expenses (itemized) Number
Number
~P I
~-------~= ~====~========================~=============== Nmh [ bOO fo poc l ----- ----- ============================= Number
Number Justification for expense
I Number Justification for expense
Number Justification for expense
-l
Cover Letter
The main purpose of this research is to decrease the cost of implementing a cleaner and more efficient standard in the construction of an automobile engine Forced induction is a process in which air is forced into an engine at above atmospheric pressure creating a better environment for the fuel to burn The most obvious benefits are the increases in power output and the decrease in emissions The reason however that these methods are not more commonly applied in standard consumer vehicles is the increased cost
The benefits of adding forced induction are already well known and have been implemented in commercial engines since 1938 Most of the research already conducted shows significant gains in power and emissions Complications are derived from handling the added power and heat Two common applications of forced induction are the Turbocharger and the supercharger one running off of exhaust fumes and the other off of the rotation of the engine For this purpose using the supercharger model for integration appears to be simpler to apply in the space constraints of a cylinder head
By integrating the forced induction unit into the cylinder head the goal is to simplify the overall system to the most essential components and close the distances included in traditional applications The reduction of parts lowers costs and the shorter operating distances reduces extraneous stresses on components along with decreasing the space needed for the system to occupy By minimizing the amount of highly pressurized air sections of the system there will be less excess heat being generated to decrease the power output
The automotive industry is always looking for more ways to increase efficiency and lower emissions whether it is from competition or by government regulation The University of Idaho already has many resources dedicated to high efficiency vehicle research leaving not much left to buy outside materials needed to build a functional prototype and a used engine to be tested on Such a prototype can be easily patented and marketed by the University to companies to be licensed out
The main requirements are could best be envisioned as a inline-four-cylinder engine on a working motorcycle chassis A complete system motorcycle system would come with all the fuel ignition and extraneous parts needed for testing The university already has computer aided design programs for designing considerable machining capacity and testing facilities for the full prototype process to be maintained completely in-house Other substantial expenses would be derived from bearings geais and other miscellaneous parts
My own personal passion for automobiles and desire to work in said industry leads me to believe this endeavor will positively impact my career as a mechanical engineer as well as the universitys reputation as a leader in innovation
Narrative
Objectives
Reduce the number of parts
By using the cylinder head as the main mount for the whole assembly general parts
from a supercharger can be integrated into head 5uch items as the corkscrew or other pressure
increasing turbine blade can be mated right at the entrance of each induction port To power
the spinning blades a gear assembly can be ran directly off the camshaft Lubricant and cooling
that already runs through the head can be redirected within the head assembly to reduce the
burden on pumps
Reduce power losses from heat
A major consideration when upgrading a naturally aspirated to forced induction in
managing the heat created by pressurizing air (52) As a higher intake temperature in the air
results in power losses the introduction of intercoolers is used to cool the air down before it
enters the engine By minimizing the distance traveled by the pressurized air the amount of air
that is pressurized at a moment in time can also be minimized and less pressurized air moving
to the engine will reduce the amount of heat generated and therefore minimize power loss in
that area
Lower Emissions
When the gas enters the combustion chamber at a higher than atmospheric pressure
there are more oxygen molecules per unit of air to contribute to the combustion of the fuel
This allows for the more efficient burning of the fuel leaving less undesirable molecules such as
carbon monoxide With less fuel being burned per unit of power obtained a car fitted with this
application can lower its carbon dioxide emissions without compromising on the desired power
output With ever increasing demands on emissions by the government developments in
cheaper ways to lower emissions on current petroleum driven engines is sure to be in demand
Room for future development
This development can be seen as a stepping stone to future developments in the
continuous improvements of internal combustion engines Once power gains have been
established with forced induction applications the lower engine block can begin to be resized
for the proper displacement along with compensation for the higher power demands of the
lower engine components
Importance
Improved Power Output amp Lower Cost
Horsepower ratings are a big selling point in the purchasing of an automobile more so
in the United States than other markets So the opportunity of having similar power gains for
less cost than traditional forced induction applications makes this alternative a worthy
consideration
Lower Emissions amp Higher efficiency
With the United States Government constantly trying to reduce greenhouse gasses
created by automobile emissions they are requiring cars to from manufacturers to have an
average mpg rating of 42 or more by 2016 (53) The allure of the same power ratings with less
fuel consumption again makes this a golden opportunity to benefit the whole industry
Minimizing Cons of Forced Induction
The goal of this research is to address the problems created by implementing a forced
induction system Along with lubrication and heating issues addressed earlier there are other
benefits that can result from this system With the lack of distance created by long pressurized
tubes the effective lag in power can hopefully be minimized and the need for a pressure
release valve can be negated all together This will further enforce the benefit of an integrated
system over a traditional one
Methods
CAD Prototype Design
The first phase of the design process is to make a prototype in the three dimensional
environment using computer aided design Using the already existing sophisticated equipment
already owned by the University of Idaho it is possible to use a program such as Catia to model
the prototype Modeling the prototype in this program will allow for the optimization of space
usage in the design Features included in this program such as the Finite Element Analysis tools
will aid in minimizing materials and costs down the road
A generalized model can be obtained via the experimental head unit purchased for the
experiment From there modifications can be added in the 3D program in order to include a
forced induction system Everything from the bearings to the fasteners can be modeled and
accounted for in a final bill of materials
By the iteration process the design would be continuously improved in order to keep it
as simple as possible to machine and assemble The Finite Element Analysis tools can be used to
analyze forces applied to the assembly Other programs such as Genesis can find material that
isnt supporting a load and can therefore be optimized for necessary strength and minimizing
the overall product weight It will also be designed to minimize the number of custom parts
that need to be made in favor for parts available for purchasing The overall goal is to keep
manufacturing costs down and maximize the efficiency of the unit
When the final assembly is complete and ready to be prepped for machining a
complete drawing package can be created for every individual custom part that is to be
manufactured as well as accounting for all the necessary fasteners bearings and other
miscellaneous parts that used for incorporating forced induction
Machining amp Assembly
This section will be the most labor intensive section of the process As much coding is
needed to set up such a relatively complicated part not to mention the time it takes to machine
the parts themselves However the University of Idaho has a CNC Mill that has the capacity for
the machining required While porting and relieving the heads needs a multi-axis mill such
operations can be avoided in favor of editing an existing head unit or making a unit from
scratch to our own capabilities The goal would be to limit machining time to less than 50 hours
of machining
During the assembly phase attention to tolerances is of utmost importance to maintain
the best possible quality and a high life cycle for the unit At this point the cost of miscellaneous
parts comes into play with the correct application of the proper bearings fasteners and other
part sizes This is of course with consideration for part standardization and cost minimization
Testing amp Tuning
This phase will include the optimization of power output and fuel consumption The
facilities available allow us to digitally monitor many aspects of the engine while it is running
By analyzing the collected data the system can be changed accordingly whether it be the
ignition timing compression ratios or valve moment among many other options From the
results we can obtain proper comparisons between the new forced induction system and a
naturally aspirated system
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
------
------
-----
-----
------
-----
-----
--------------------------------
Name Eric SpragueSTUDENT GRANT PROGRAM Project Grant Budget Form Please fill out this form usning Adobe Acrobat Student 10 081-36997
t (t d) for all expenses listed under EquipOlent indicate on page 2 of tl is PDf who will aSSUOle responsibility AmountEqUlpmen I emlze for the equipOlent once the project has been completed
1 Used 4cl Engine or Running 4cl Motorcycle $2000
$000 2
$0003
$0004
$0005
Materials and Supplies (itemized)
1 Aluminum Stock
2 Miscellaneous Parts
3 Tooling materials
4
5
Equipment total _$_20_0_0___
$300
$700
$100
$000
$000
Travet Costs (itemized)
1 List items Here
2
3
4
5
Materials and supplies total _$_1_00_0___
$000
$000
$000
$000
$000
Travel total $000----shyPersonnelServices (itemized)
1 Master Machinist Assistance $1600
2 $000
3 $000
4 $000
5 $000
Personnelservices total _$_0_0_0___ Other Expenses (itemized) All items listed under Other Expenses must be accompanied by a justification statement on the 2 page of this PDf
1 List Items Here $0 00
2 $0 00
3 $0 00
~ WOO -----
5 $000 ------
6 $000
7 $000
Other total $000
Subtotal $4600
Facilities and Administrative Costs (800) _$_36_8___
Your Current Total $000
Total must NOT EXCEED $500000 Total Request _$4_9_68__
----------------------------
11
Justification - For all expenses over $100 and those items listed under Other Expenses describe the expenses such
that reviewers and committee members will be able to immediately recognize the relevance and necessity of the items
For all expenses listed under Equipment indicate who will assume responsibility for the equipment once the project
has been completed
Equipment (itemized)
Number Who will assume responsibility for the equipment once the project has been completed
iThe Master Machinist of the University of Idaho
Justification for expense if over $100
As the prototype is a component of the engine assembly a strong four cylinder engine is required to model the application of multiple cylinders The unit must also be able to withstand higher power outputs
Number
I Justification for expense if over $100
Who will assume responsibility for the equipment once the project has been completed
Number Who will assume responsibility for the equipment once the project has been completed
I
Number Who will assume responsibility for the equipment once the project has been completed
Justification for expense if over $100 --------------------------------------------------~
Number
Justification for expense if over $100 ----------------------------------------------------~
I
PersonnelServices (itemized) For all expenses over $100
Number Justification for expense
rThe Master Machinist Russ Porter is an invaluable resource He is constantly giving insi~t-to better ] II ~c~chining through economy and ingenuity Whatever the University pays him its not enough The ~imates are based on above average machinist pay at about 80 hours of contribution
----------------
Number ~stificatio n fo~ expense-______________ --_
Number Justification for expense
I Justification for expe se n~_______________________________Number
Number Justification for ex ense _~~____- ___---___-~________________
Other Expenses (itemized) Number
Number
~P I
~-------~= ~====~========================~=============== Nmh [ bOO fo poc l ----- ----- ============================= Number
Number Justification for expense
I Number Justification for expense
Number Justification for expense
-l
Cover Letter
The main purpose of this research is to decrease the cost of implementing a cleaner and more efficient standard in the construction of an automobile engine Forced induction is a process in which air is forced into an engine at above atmospheric pressure creating a better environment for the fuel to burn The most obvious benefits are the increases in power output and the decrease in emissions The reason however that these methods are not more commonly applied in standard consumer vehicles is the increased cost
The benefits of adding forced induction are already well known and have been implemented in commercial engines since 1938 Most of the research already conducted shows significant gains in power and emissions Complications are derived from handling the added power and heat Two common applications of forced induction are the Turbocharger and the supercharger one running off of exhaust fumes and the other off of the rotation of the engine For this purpose using the supercharger model for integration appears to be simpler to apply in the space constraints of a cylinder head
By integrating the forced induction unit into the cylinder head the goal is to simplify the overall system to the most essential components and close the distances included in traditional applications The reduction of parts lowers costs and the shorter operating distances reduces extraneous stresses on components along with decreasing the space needed for the system to occupy By minimizing the amount of highly pressurized air sections of the system there will be less excess heat being generated to decrease the power output
The automotive industry is always looking for more ways to increase efficiency and lower emissions whether it is from competition or by government regulation The University of Idaho already has many resources dedicated to high efficiency vehicle research leaving not much left to buy outside materials needed to build a functional prototype and a used engine to be tested on Such a prototype can be easily patented and marketed by the University to companies to be licensed out
The main requirements are could best be envisioned as a inline-four-cylinder engine on a working motorcycle chassis A complete system motorcycle system would come with all the fuel ignition and extraneous parts needed for testing The university already has computer aided design programs for designing considerable machining capacity and testing facilities for the full prototype process to be maintained completely in-house Other substantial expenses would be derived from bearings geais and other miscellaneous parts
My own personal passion for automobiles and desire to work in said industry leads me to believe this endeavor will positively impact my career as a mechanical engineer as well as the universitys reputation as a leader in innovation
Narrative
Objectives
Reduce the number of parts
By using the cylinder head as the main mount for the whole assembly general parts
from a supercharger can be integrated into head 5uch items as the corkscrew or other pressure
increasing turbine blade can be mated right at the entrance of each induction port To power
the spinning blades a gear assembly can be ran directly off the camshaft Lubricant and cooling
that already runs through the head can be redirected within the head assembly to reduce the
burden on pumps
Reduce power losses from heat
A major consideration when upgrading a naturally aspirated to forced induction in
managing the heat created by pressurizing air (52) As a higher intake temperature in the air
results in power losses the introduction of intercoolers is used to cool the air down before it
enters the engine By minimizing the distance traveled by the pressurized air the amount of air
that is pressurized at a moment in time can also be minimized and less pressurized air moving
to the engine will reduce the amount of heat generated and therefore minimize power loss in
that area
Lower Emissions
When the gas enters the combustion chamber at a higher than atmospheric pressure
there are more oxygen molecules per unit of air to contribute to the combustion of the fuel
This allows for the more efficient burning of the fuel leaving less undesirable molecules such as
carbon monoxide With less fuel being burned per unit of power obtained a car fitted with this
application can lower its carbon dioxide emissions without compromising on the desired power
output With ever increasing demands on emissions by the government developments in
cheaper ways to lower emissions on current petroleum driven engines is sure to be in demand
Room for future development
This development can be seen as a stepping stone to future developments in the
continuous improvements of internal combustion engines Once power gains have been
established with forced induction applications the lower engine block can begin to be resized
for the proper displacement along with compensation for the higher power demands of the
lower engine components
Importance
Improved Power Output amp Lower Cost
Horsepower ratings are a big selling point in the purchasing of an automobile more so
in the United States than other markets So the opportunity of having similar power gains for
less cost than traditional forced induction applications makes this alternative a worthy
consideration
Lower Emissions amp Higher efficiency
With the United States Government constantly trying to reduce greenhouse gasses
created by automobile emissions they are requiring cars to from manufacturers to have an
average mpg rating of 42 or more by 2016 (53) The allure of the same power ratings with less
fuel consumption again makes this a golden opportunity to benefit the whole industry
Minimizing Cons of Forced Induction
The goal of this research is to address the problems created by implementing a forced
induction system Along with lubrication and heating issues addressed earlier there are other
benefits that can result from this system With the lack of distance created by long pressurized
tubes the effective lag in power can hopefully be minimized and the need for a pressure
release valve can be negated all together This will further enforce the benefit of an integrated
system over a traditional one
Methods
CAD Prototype Design
The first phase of the design process is to make a prototype in the three dimensional
environment using computer aided design Using the already existing sophisticated equipment
already owned by the University of Idaho it is possible to use a program such as Catia to model
the prototype Modeling the prototype in this program will allow for the optimization of space
usage in the design Features included in this program such as the Finite Element Analysis tools
will aid in minimizing materials and costs down the road
A generalized model can be obtained via the experimental head unit purchased for the
experiment From there modifications can be added in the 3D program in order to include a
forced induction system Everything from the bearings to the fasteners can be modeled and
accounted for in a final bill of materials
By the iteration process the design would be continuously improved in order to keep it
as simple as possible to machine and assemble The Finite Element Analysis tools can be used to
analyze forces applied to the assembly Other programs such as Genesis can find material that
isnt supporting a load and can therefore be optimized for necessary strength and minimizing
the overall product weight It will also be designed to minimize the number of custom parts
that need to be made in favor for parts available for purchasing The overall goal is to keep
manufacturing costs down and maximize the efficiency of the unit
When the final assembly is complete and ready to be prepped for machining a
complete drawing package can be created for every individual custom part that is to be
manufactured as well as accounting for all the necessary fasteners bearings and other
miscellaneous parts that used for incorporating forced induction
Machining amp Assembly
This section will be the most labor intensive section of the process As much coding is
needed to set up such a relatively complicated part not to mention the time it takes to machine
the parts themselves However the University of Idaho has a CNC Mill that has the capacity for
the machining required While porting and relieving the heads needs a multi-axis mill such
operations can be avoided in favor of editing an existing head unit or making a unit from
scratch to our own capabilities The goal would be to limit machining time to less than 50 hours
of machining
During the assembly phase attention to tolerances is of utmost importance to maintain
the best possible quality and a high life cycle for the unit At this point the cost of miscellaneous
parts comes into play with the correct application of the proper bearings fasteners and other
part sizes This is of course with consideration for part standardization and cost minimization
Testing amp Tuning
This phase will include the optimization of power output and fuel consumption The
facilities available allow us to digitally monitor many aspects of the engine while it is running
By analyzing the collected data the system can be changed accordingly whether it be the
ignition timing compression ratios or valve moment among many other options From the
results we can obtain proper comparisons between the new forced induction system and a
naturally aspirated system
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
----------------------------
11
Justification - For all expenses over $100 and those items listed under Other Expenses describe the expenses such
that reviewers and committee members will be able to immediately recognize the relevance and necessity of the items
For all expenses listed under Equipment indicate who will assume responsibility for the equipment once the project
has been completed
Equipment (itemized)
Number Who will assume responsibility for the equipment once the project has been completed
iThe Master Machinist of the University of Idaho
Justification for expense if over $100
As the prototype is a component of the engine assembly a strong four cylinder engine is required to model the application of multiple cylinders The unit must also be able to withstand higher power outputs
Number
I Justification for expense if over $100
Who will assume responsibility for the equipment once the project has been completed
Number Who will assume responsibility for the equipment once the project has been completed
I
Number Who will assume responsibility for the equipment once the project has been completed
Justification for expense if over $100 --------------------------------------------------~
Number
Justification for expense if over $100 ----------------------------------------------------~
I
PersonnelServices (itemized) For all expenses over $100
Number Justification for expense
rThe Master Machinist Russ Porter is an invaluable resource He is constantly giving insi~t-to better ] II ~c~chining through economy and ingenuity Whatever the University pays him its not enough The ~imates are based on above average machinist pay at about 80 hours of contribution
----------------
Number ~stificatio n fo~ expense-______________ --_
Number Justification for expense
I Justification for expe se n~_______________________________Number
Number Justification for ex ense _~~____- ___---___-~________________
Other Expenses (itemized) Number
Number
~P I
~-------~= ~====~========================~=============== Nmh [ bOO fo poc l ----- ----- ============================= Number
Number Justification for expense
I Number Justification for expense
Number Justification for expense
-l
Cover Letter
The main purpose of this research is to decrease the cost of implementing a cleaner and more efficient standard in the construction of an automobile engine Forced induction is a process in which air is forced into an engine at above atmospheric pressure creating a better environment for the fuel to burn The most obvious benefits are the increases in power output and the decrease in emissions The reason however that these methods are not more commonly applied in standard consumer vehicles is the increased cost
The benefits of adding forced induction are already well known and have been implemented in commercial engines since 1938 Most of the research already conducted shows significant gains in power and emissions Complications are derived from handling the added power and heat Two common applications of forced induction are the Turbocharger and the supercharger one running off of exhaust fumes and the other off of the rotation of the engine For this purpose using the supercharger model for integration appears to be simpler to apply in the space constraints of a cylinder head
By integrating the forced induction unit into the cylinder head the goal is to simplify the overall system to the most essential components and close the distances included in traditional applications The reduction of parts lowers costs and the shorter operating distances reduces extraneous stresses on components along with decreasing the space needed for the system to occupy By minimizing the amount of highly pressurized air sections of the system there will be less excess heat being generated to decrease the power output
The automotive industry is always looking for more ways to increase efficiency and lower emissions whether it is from competition or by government regulation The University of Idaho already has many resources dedicated to high efficiency vehicle research leaving not much left to buy outside materials needed to build a functional prototype and a used engine to be tested on Such a prototype can be easily patented and marketed by the University to companies to be licensed out
The main requirements are could best be envisioned as a inline-four-cylinder engine on a working motorcycle chassis A complete system motorcycle system would come with all the fuel ignition and extraneous parts needed for testing The university already has computer aided design programs for designing considerable machining capacity and testing facilities for the full prototype process to be maintained completely in-house Other substantial expenses would be derived from bearings geais and other miscellaneous parts
My own personal passion for automobiles and desire to work in said industry leads me to believe this endeavor will positively impact my career as a mechanical engineer as well as the universitys reputation as a leader in innovation
Narrative
Objectives
Reduce the number of parts
By using the cylinder head as the main mount for the whole assembly general parts
from a supercharger can be integrated into head 5uch items as the corkscrew or other pressure
increasing turbine blade can be mated right at the entrance of each induction port To power
the spinning blades a gear assembly can be ran directly off the camshaft Lubricant and cooling
that already runs through the head can be redirected within the head assembly to reduce the
burden on pumps
Reduce power losses from heat
A major consideration when upgrading a naturally aspirated to forced induction in
managing the heat created by pressurizing air (52) As a higher intake temperature in the air
results in power losses the introduction of intercoolers is used to cool the air down before it
enters the engine By minimizing the distance traveled by the pressurized air the amount of air
that is pressurized at a moment in time can also be minimized and less pressurized air moving
to the engine will reduce the amount of heat generated and therefore minimize power loss in
that area
Lower Emissions
When the gas enters the combustion chamber at a higher than atmospheric pressure
there are more oxygen molecules per unit of air to contribute to the combustion of the fuel
This allows for the more efficient burning of the fuel leaving less undesirable molecules such as
carbon monoxide With less fuel being burned per unit of power obtained a car fitted with this
application can lower its carbon dioxide emissions without compromising on the desired power
output With ever increasing demands on emissions by the government developments in
cheaper ways to lower emissions on current petroleum driven engines is sure to be in demand
Room for future development
This development can be seen as a stepping stone to future developments in the
continuous improvements of internal combustion engines Once power gains have been
established with forced induction applications the lower engine block can begin to be resized
for the proper displacement along with compensation for the higher power demands of the
lower engine components
Importance
Improved Power Output amp Lower Cost
Horsepower ratings are a big selling point in the purchasing of an automobile more so
in the United States than other markets So the opportunity of having similar power gains for
less cost than traditional forced induction applications makes this alternative a worthy
consideration
Lower Emissions amp Higher efficiency
With the United States Government constantly trying to reduce greenhouse gasses
created by automobile emissions they are requiring cars to from manufacturers to have an
average mpg rating of 42 or more by 2016 (53) The allure of the same power ratings with less
fuel consumption again makes this a golden opportunity to benefit the whole industry
Minimizing Cons of Forced Induction
The goal of this research is to address the problems created by implementing a forced
induction system Along with lubrication and heating issues addressed earlier there are other
benefits that can result from this system With the lack of distance created by long pressurized
tubes the effective lag in power can hopefully be minimized and the need for a pressure
release valve can be negated all together This will further enforce the benefit of an integrated
system over a traditional one
Methods
CAD Prototype Design
The first phase of the design process is to make a prototype in the three dimensional
environment using computer aided design Using the already existing sophisticated equipment
already owned by the University of Idaho it is possible to use a program such as Catia to model
the prototype Modeling the prototype in this program will allow for the optimization of space
usage in the design Features included in this program such as the Finite Element Analysis tools
will aid in minimizing materials and costs down the road
A generalized model can be obtained via the experimental head unit purchased for the
experiment From there modifications can be added in the 3D program in order to include a
forced induction system Everything from the bearings to the fasteners can be modeled and
accounted for in a final bill of materials
By the iteration process the design would be continuously improved in order to keep it
as simple as possible to machine and assemble The Finite Element Analysis tools can be used to
analyze forces applied to the assembly Other programs such as Genesis can find material that
isnt supporting a load and can therefore be optimized for necessary strength and minimizing
the overall product weight It will also be designed to minimize the number of custom parts
that need to be made in favor for parts available for purchasing The overall goal is to keep
manufacturing costs down and maximize the efficiency of the unit
When the final assembly is complete and ready to be prepped for machining a
complete drawing package can be created for every individual custom part that is to be
manufactured as well as accounting for all the necessary fasteners bearings and other
miscellaneous parts that used for incorporating forced induction
Machining amp Assembly
This section will be the most labor intensive section of the process As much coding is
needed to set up such a relatively complicated part not to mention the time it takes to machine
the parts themselves However the University of Idaho has a CNC Mill that has the capacity for
the machining required While porting and relieving the heads needs a multi-axis mill such
operations can be avoided in favor of editing an existing head unit or making a unit from
scratch to our own capabilities The goal would be to limit machining time to less than 50 hours
of machining
During the assembly phase attention to tolerances is of utmost importance to maintain
the best possible quality and a high life cycle for the unit At this point the cost of miscellaneous
parts comes into play with the correct application of the proper bearings fasteners and other
part sizes This is of course with consideration for part standardization and cost minimization
Testing amp Tuning
This phase will include the optimization of power output and fuel consumption The
facilities available allow us to digitally monitor many aspects of the engine while it is running
By analyzing the collected data the system can be changed accordingly whether it be the
ignition timing compression ratios or valve moment among many other options From the
results we can obtain proper comparisons between the new forced induction system and a
naturally aspirated system
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
I
PersonnelServices (itemized) For all expenses over $100
Number Justification for expense
rThe Master Machinist Russ Porter is an invaluable resource He is constantly giving insi~t-to better ] II ~c~chining through economy and ingenuity Whatever the University pays him its not enough The ~imates are based on above average machinist pay at about 80 hours of contribution
----------------
Number ~stificatio n fo~ expense-______________ --_
Number Justification for expense
I Justification for expe se n~_______________________________Number
Number Justification for ex ense _~~____- ___---___-~________________
Other Expenses (itemized) Number
Number
~P I
~-------~= ~====~========================~=============== Nmh [ bOO fo poc l ----- ----- ============================= Number
Number Justification for expense
I Number Justification for expense
Number Justification for expense
-l
Cover Letter
The main purpose of this research is to decrease the cost of implementing a cleaner and more efficient standard in the construction of an automobile engine Forced induction is a process in which air is forced into an engine at above atmospheric pressure creating a better environment for the fuel to burn The most obvious benefits are the increases in power output and the decrease in emissions The reason however that these methods are not more commonly applied in standard consumer vehicles is the increased cost
The benefits of adding forced induction are already well known and have been implemented in commercial engines since 1938 Most of the research already conducted shows significant gains in power and emissions Complications are derived from handling the added power and heat Two common applications of forced induction are the Turbocharger and the supercharger one running off of exhaust fumes and the other off of the rotation of the engine For this purpose using the supercharger model for integration appears to be simpler to apply in the space constraints of a cylinder head
By integrating the forced induction unit into the cylinder head the goal is to simplify the overall system to the most essential components and close the distances included in traditional applications The reduction of parts lowers costs and the shorter operating distances reduces extraneous stresses on components along with decreasing the space needed for the system to occupy By minimizing the amount of highly pressurized air sections of the system there will be less excess heat being generated to decrease the power output
The automotive industry is always looking for more ways to increase efficiency and lower emissions whether it is from competition or by government regulation The University of Idaho already has many resources dedicated to high efficiency vehicle research leaving not much left to buy outside materials needed to build a functional prototype and a used engine to be tested on Such a prototype can be easily patented and marketed by the University to companies to be licensed out
The main requirements are could best be envisioned as a inline-four-cylinder engine on a working motorcycle chassis A complete system motorcycle system would come with all the fuel ignition and extraneous parts needed for testing The university already has computer aided design programs for designing considerable machining capacity and testing facilities for the full prototype process to be maintained completely in-house Other substantial expenses would be derived from bearings geais and other miscellaneous parts
My own personal passion for automobiles and desire to work in said industry leads me to believe this endeavor will positively impact my career as a mechanical engineer as well as the universitys reputation as a leader in innovation
Narrative
Objectives
Reduce the number of parts
By using the cylinder head as the main mount for the whole assembly general parts
from a supercharger can be integrated into head 5uch items as the corkscrew or other pressure
increasing turbine blade can be mated right at the entrance of each induction port To power
the spinning blades a gear assembly can be ran directly off the camshaft Lubricant and cooling
that already runs through the head can be redirected within the head assembly to reduce the
burden on pumps
Reduce power losses from heat
A major consideration when upgrading a naturally aspirated to forced induction in
managing the heat created by pressurizing air (52) As a higher intake temperature in the air
results in power losses the introduction of intercoolers is used to cool the air down before it
enters the engine By minimizing the distance traveled by the pressurized air the amount of air
that is pressurized at a moment in time can also be minimized and less pressurized air moving
to the engine will reduce the amount of heat generated and therefore minimize power loss in
that area
Lower Emissions
When the gas enters the combustion chamber at a higher than atmospheric pressure
there are more oxygen molecules per unit of air to contribute to the combustion of the fuel
This allows for the more efficient burning of the fuel leaving less undesirable molecules such as
carbon monoxide With less fuel being burned per unit of power obtained a car fitted with this
application can lower its carbon dioxide emissions without compromising on the desired power
output With ever increasing demands on emissions by the government developments in
cheaper ways to lower emissions on current petroleum driven engines is sure to be in demand
Room for future development
This development can be seen as a stepping stone to future developments in the
continuous improvements of internal combustion engines Once power gains have been
established with forced induction applications the lower engine block can begin to be resized
for the proper displacement along with compensation for the higher power demands of the
lower engine components
Importance
Improved Power Output amp Lower Cost
Horsepower ratings are a big selling point in the purchasing of an automobile more so
in the United States than other markets So the opportunity of having similar power gains for
less cost than traditional forced induction applications makes this alternative a worthy
consideration
Lower Emissions amp Higher efficiency
With the United States Government constantly trying to reduce greenhouse gasses
created by automobile emissions they are requiring cars to from manufacturers to have an
average mpg rating of 42 or more by 2016 (53) The allure of the same power ratings with less
fuel consumption again makes this a golden opportunity to benefit the whole industry
Minimizing Cons of Forced Induction
The goal of this research is to address the problems created by implementing a forced
induction system Along with lubrication and heating issues addressed earlier there are other
benefits that can result from this system With the lack of distance created by long pressurized
tubes the effective lag in power can hopefully be minimized and the need for a pressure
release valve can be negated all together This will further enforce the benefit of an integrated
system over a traditional one
Methods
CAD Prototype Design
The first phase of the design process is to make a prototype in the three dimensional
environment using computer aided design Using the already existing sophisticated equipment
already owned by the University of Idaho it is possible to use a program such as Catia to model
the prototype Modeling the prototype in this program will allow for the optimization of space
usage in the design Features included in this program such as the Finite Element Analysis tools
will aid in minimizing materials and costs down the road
A generalized model can be obtained via the experimental head unit purchased for the
experiment From there modifications can be added in the 3D program in order to include a
forced induction system Everything from the bearings to the fasteners can be modeled and
accounted for in a final bill of materials
By the iteration process the design would be continuously improved in order to keep it
as simple as possible to machine and assemble The Finite Element Analysis tools can be used to
analyze forces applied to the assembly Other programs such as Genesis can find material that
isnt supporting a load and can therefore be optimized for necessary strength and minimizing
the overall product weight It will also be designed to minimize the number of custom parts
that need to be made in favor for parts available for purchasing The overall goal is to keep
manufacturing costs down and maximize the efficiency of the unit
When the final assembly is complete and ready to be prepped for machining a
complete drawing package can be created for every individual custom part that is to be
manufactured as well as accounting for all the necessary fasteners bearings and other
miscellaneous parts that used for incorporating forced induction
Machining amp Assembly
This section will be the most labor intensive section of the process As much coding is
needed to set up such a relatively complicated part not to mention the time it takes to machine
the parts themselves However the University of Idaho has a CNC Mill that has the capacity for
the machining required While porting and relieving the heads needs a multi-axis mill such
operations can be avoided in favor of editing an existing head unit or making a unit from
scratch to our own capabilities The goal would be to limit machining time to less than 50 hours
of machining
During the assembly phase attention to tolerances is of utmost importance to maintain
the best possible quality and a high life cycle for the unit At this point the cost of miscellaneous
parts comes into play with the correct application of the proper bearings fasteners and other
part sizes This is of course with consideration for part standardization and cost minimization
Testing amp Tuning
This phase will include the optimization of power output and fuel consumption The
facilities available allow us to digitally monitor many aspects of the engine while it is running
By analyzing the collected data the system can be changed accordingly whether it be the
ignition timing compression ratios or valve moment among many other options From the
results we can obtain proper comparisons between the new forced induction system and a
naturally aspirated system
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
Cover Letter
The main purpose of this research is to decrease the cost of implementing a cleaner and more efficient standard in the construction of an automobile engine Forced induction is a process in which air is forced into an engine at above atmospheric pressure creating a better environment for the fuel to burn The most obvious benefits are the increases in power output and the decrease in emissions The reason however that these methods are not more commonly applied in standard consumer vehicles is the increased cost
The benefits of adding forced induction are already well known and have been implemented in commercial engines since 1938 Most of the research already conducted shows significant gains in power and emissions Complications are derived from handling the added power and heat Two common applications of forced induction are the Turbocharger and the supercharger one running off of exhaust fumes and the other off of the rotation of the engine For this purpose using the supercharger model for integration appears to be simpler to apply in the space constraints of a cylinder head
By integrating the forced induction unit into the cylinder head the goal is to simplify the overall system to the most essential components and close the distances included in traditional applications The reduction of parts lowers costs and the shorter operating distances reduces extraneous stresses on components along with decreasing the space needed for the system to occupy By minimizing the amount of highly pressurized air sections of the system there will be less excess heat being generated to decrease the power output
The automotive industry is always looking for more ways to increase efficiency and lower emissions whether it is from competition or by government regulation The University of Idaho already has many resources dedicated to high efficiency vehicle research leaving not much left to buy outside materials needed to build a functional prototype and a used engine to be tested on Such a prototype can be easily patented and marketed by the University to companies to be licensed out
The main requirements are could best be envisioned as a inline-four-cylinder engine on a working motorcycle chassis A complete system motorcycle system would come with all the fuel ignition and extraneous parts needed for testing The university already has computer aided design programs for designing considerable machining capacity and testing facilities for the full prototype process to be maintained completely in-house Other substantial expenses would be derived from bearings geais and other miscellaneous parts
My own personal passion for automobiles and desire to work in said industry leads me to believe this endeavor will positively impact my career as a mechanical engineer as well as the universitys reputation as a leader in innovation
Narrative
Objectives
Reduce the number of parts
By using the cylinder head as the main mount for the whole assembly general parts
from a supercharger can be integrated into head 5uch items as the corkscrew or other pressure
increasing turbine blade can be mated right at the entrance of each induction port To power
the spinning blades a gear assembly can be ran directly off the camshaft Lubricant and cooling
that already runs through the head can be redirected within the head assembly to reduce the
burden on pumps
Reduce power losses from heat
A major consideration when upgrading a naturally aspirated to forced induction in
managing the heat created by pressurizing air (52) As a higher intake temperature in the air
results in power losses the introduction of intercoolers is used to cool the air down before it
enters the engine By minimizing the distance traveled by the pressurized air the amount of air
that is pressurized at a moment in time can also be minimized and less pressurized air moving
to the engine will reduce the amount of heat generated and therefore minimize power loss in
that area
Lower Emissions
When the gas enters the combustion chamber at a higher than atmospheric pressure
there are more oxygen molecules per unit of air to contribute to the combustion of the fuel
This allows for the more efficient burning of the fuel leaving less undesirable molecules such as
carbon monoxide With less fuel being burned per unit of power obtained a car fitted with this
application can lower its carbon dioxide emissions without compromising on the desired power
output With ever increasing demands on emissions by the government developments in
cheaper ways to lower emissions on current petroleum driven engines is sure to be in demand
Room for future development
This development can be seen as a stepping stone to future developments in the
continuous improvements of internal combustion engines Once power gains have been
established with forced induction applications the lower engine block can begin to be resized
for the proper displacement along with compensation for the higher power demands of the
lower engine components
Importance
Improved Power Output amp Lower Cost
Horsepower ratings are a big selling point in the purchasing of an automobile more so
in the United States than other markets So the opportunity of having similar power gains for
less cost than traditional forced induction applications makes this alternative a worthy
consideration
Lower Emissions amp Higher efficiency
With the United States Government constantly trying to reduce greenhouse gasses
created by automobile emissions they are requiring cars to from manufacturers to have an
average mpg rating of 42 or more by 2016 (53) The allure of the same power ratings with less
fuel consumption again makes this a golden opportunity to benefit the whole industry
Minimizing Cons of Forced Induction
The goal of this research is to address the problems created by implementing a forced
induction system Along with lubrication and heating issues addressed earlier there are other
benefits that can result from this system With the lack of distance created by long pressurized
tubes the effective lag in power can hopefully be minimized and the need for a pressure
release valve can be negated all together This will further enforce the benefit of an integrated
system over a traditional one
Methods
CAD Prototype Design
The first phase of the design process is to make a prototype in the three dimensional
environment using computer aided design Using the already existing sophisticated equipment
already owned by the University of Idaho it is possible to use a program such as Catia to model
the prototype Modeling the prototype in this program will allow for the optimization of space
usage in the design Features included in this program such as the Finite Element Analysis tools
will aid in minimizing materials and costs down the road
A generalized model can be obtained via the experimental head unit purchased for the
experiment From there modifications can be added in the 3D program in order to include a
forced induction system Everything from the bearings to the fasteners can be modeled and
accounted for in a final bill of materials
By the iteration process the design would be continuously improved in order to keep it
as simple as possible to machine and assemble The Finite Element Analysis tools can be used to
analyze forces applied to the assembly Other programs such as Genesis can find material that
isnt supporting a load and can therefore be optimized for necessary strength and minimizing
the overall product weight It will also be designed to minimize the number of custom parts
that need to be made in favor for parts available for purchasing The overall goal is to keep
manufacturing costs down and maximize the efficiency of the unit
When the final assembly is complete and ready to be prepped for machining a
complete drawing package can be created for every individual custom part that is to be
manufactured as well as accounting for all the necessary fasteners bearings and other
miscellaneous parts that used for incorporating forced induction
Machining amp Assembly
This section will be the most labor intensive section of the process As much coding is
needed to set up such a relatively complicated part not to mention the time it takes to machine
the parts themselves However the University of Idaho has a CNC Mill that has the capacity for
the machining required While porting and relieving the heads needs a multi-axis mill such
operations can be avoided in favor of editing an existing head unit or making a unit from
scratch to our own capabilities The goal would be to limit machining time to less than 50 hours
of machining
During the assembly phase attention to tolerances is of utmost importance to maintain
the best possible quality and a high life cycle for the unit At this point the cost of miscellaneous
parts comes into play with the correct application of the proper bearings fasteners and other
part sizes This is of course with consideration for part standardization and cost minimization
Testing amp Tuning
This phase will include the optimization of power output and fuel consumption The
facilities available allow us to digitally monitor many aspects of the engine while it is running
By analyzing the collected data the system can be changed accordingly whether it be the
ignition timing compression ratios or valve moment among many other options From the
results we can obtain proper comparisons between the new forced induction system and a
naturally aspirated system
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
Narrative
Objectives
Reduce the number of parts
By using the cylinder head as the main mount for the whole assembly general parts
from a supercharger can be integrated into head 5uch items as the corkscrew or other pressure
increasing turbine blade can be mated right at the entrance of each induction port To power
the spinning blades a gear assembly can be ran directly off the camshaft Lubricant and cooling
that already runs through the head can be redirected within the head assembly to reduce the
burden on pumps
Reduce power losses from heat
A major consideration when upgrading a naturally aspirated to forced induction in
managing the heat created by pressurizing air (52) As a higher intake temperature in the air
results in power losses the introduction of intercoolers is used to cool the air down before it
enters the engine By minimizing the distance traveled by the pressurized air the amount of air
that is pressurized at a moment in time can also be minimized and less pressurized air moving
to the engine will reduce the amount of heat generated and therefore minimize power loss in
that area
Lower Emissions
When the gas enters the combustion chamber at a higher than atmospheric pressure
there are more oxygen molecules per unit of air to contribute to the combustion of the fuel
This allows for the more efficient burning of the fuel leaving less undesirable molecules such as
carbon monoxide With less fuel being burned per unit of power obtained a car fitted with this
application can lower its carbon dioxide emissions without compromising on the desired power
output With ever increasing demands on emissions by the government developments in
cheaper ways to lower emissions on current petroleum driven engines is sure to be in demand
Room for future development
This development can be seen as a stepping stone to future developments in the
continuous improvements of internal combustion engines Once power gains have been
established with forced induction applications the lower engine block can begin to be resized
for the proper displacement along with compensation for the higher power demands of the
lower engine components
Importance
Improved Power Output amp Lower Cost
Horsepower ratings are a big selling point in the purchasing of an automobile more so
in the United States than other markets So the opportunity of having similar power gains for
less cost than traditional forced induction applications makes this alternative a worthy
consideration
Lower Emissions amp Higher efficiency
With the United States Government constantly trying to reduce greenhouse gasses
created by automobile emissions they are requiring cars to from manufacturers to have an
average mpg rating of 42 or more by 2016 (53) The allure of the same power ratings with less
fuel consumption again makes this a golden opportunity to benefit the whole industry
Minimizing Cons of Forced Induction
The goal of this research is to address the problems created by implementing a forced
induction system Along with lubrication and heating issues addressed earlier there are other
benefits that can result from this system With the lack of distance created by long pressurized
tubes the effective lag in power can hopefully be minimized and the need for a pressure
release valve can be negated all together This will further enforce the benefit of an integrated
system over a traditional one
Methods
CAD Prototype Design
The first phase of the design process is to make a prototype in the three dimensional
environment using computer aided design Using the already existing sophisticated equipment
already owned by the University of Idaho it is possible to use a program such as Catia to model
the prototype Modeling the prototype in this program will allow for the optimization of space
usage in the design Features included in this program such as the Finite Element Analysis tools
will aid in minimizing materials and costs down the road
A generalized model can be obtained via the experimental head unit purchased for the
experiment From there modifications can be added in the 3D program in order to include a
forced induction system Everything from the bearings to the fasteners can be modeled and
accounted for in a final bill of materials
By the iteration process the design would be continuously improved in order to keep it
as simple as possible to machine and assemble The Finite Element Analysis tools can be used to
analyze forces applied to the assembly Other programs such as Genesis can find material that
isnt supporting a load and can therefore be optimized for necessary strength and minimizing
the overall product weight It will also be designed to minimize the number of custom parts
that need to be made in favor for parts available for purchasing The overall goal is to keep
manufacturing costs down and maximize the efficiency of the unit
When the final assembly is complete and ready to be prepped for machining a
complete drawing package can be created for every individual custom part that is to be
manufactured as well as accounting for all the necessary fasteners bearings and other
miscellaneous parts that used for incorporating forced induction
Machining amp Assembly
This section will be the most labor intensive section of the process As much coding is
needed to set up such a relatively complicated part not to mention the time it takes to machine
the parts themselves However the University of Idaho has a CNC Mill that has the capacity for
the machining required While porting and relieving the heads needs a multi-axis mill such
operations can be avoided in favor of editing an existing head unit or making a unit from
scratch to our own capabilities The goal would be to limit machining time to less than 50 hours
of machining
During the assembly phase attention to tolerances is of utmost importance to maintain
the best possible quality and a high life cycle for the unit At this point the cost of miscellaneous
parts comes into play with the correct application of the proper bearings fasteners and other
part sizes This is of course with consideration for part standardization and cost minimization
Testing amp Tuning
This phase will include the optimization of power output and fuel consumption The
facilities available allow us to digitally monitor many aspects of the engine while it is running
By analyzing the collected data the system can be changed accordingly whether it be the
ignition timing compression ratios or valve moment among many other options From the
results we can obtain proper comparisons between the new forced induction system and a
naturally aspirated system
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
Importance
Improved Power Output amp Lower Cost
Horsepower ratings are a big selling point in the purchasing of an automobile more so
in the United States than other markets So the opportunity of having similar power gains for
less cost than traditional forced induction applications makes this alternative a worthy
consideration
Lower Emissions amp Higher efficiency
With the United States Government constantly trying to reduce greenhouse gasses
created by automobile emissions they are requiring cars to from manufacturers to have an
average mpg rating of 42 or more by 2016 (53) The allure of the same power ratings with less
fuel consumption again makes this a golden opportunity to benefit the whole industry
Minimizing Cons of Forced Induction
The goal of this research is to address the problems created by implementing a forced
induction system Along with lubrication and heating issues addressed earlier there are other
benefits that can result from this system With the lack of distance created by long pressurized
tubes the effective lag in power can hopefully be minimized and the need for a pressure
release valve can be negated all together This will further enforce the benefit of an integrated
system over a traditional one
Methods
CAD Prototype Design
The first phase of the design process is to make a prototype in the three dimensional
environment using computer aided design Using the already existing sophisticated equipment
already owned by the University of Idaho it is possible to use a program such as Catia to model
the prototype Modeling the prototype in this program will allow for the optimization of space
usage in the design Features included in this program such as the Finite Element Analysis tools
will aid in minimizing materials and costs down the road
A generalized model can be obtained via the experimental head unit purchased for the
experiment From there modifications can be added in the 3D program in order to include a
forced induction system Everything from the bearings to the fasteners can be modeled and
accounted for in a final bill of materials
By the iteration process the design would be continuously improved in order to keep it
as simple as possible to machine and assemble The Finite Element Analysis tools can be used to
analyze forces applied to the assembly Other programs such as Genesis can find material that
isnt supporting a load and can therefore be optimized for necessary strength and minimizing
the overall product weight It will also be designed to minimize the number of custom parts
that need to be made in favor for parts available for purchasing The overall goal is to keep
manufacturing costs down and maximize the efficiency of the unit
When the final assembly is complete and ready to be prepped for machining a
complete drawing package can be created for every individual custom part that is to be
manufactured as well as accounting for all the necessary fasteners bearings and other
miscellaneous parts that used for incorporating forced induction
Machining amp Assembly
This section will be the most labor intensive section of the process As much coding is
needed to set up such a relatively complicated part not to mention the time it takes to machine
the parts themselves However the University of Idaho has a CNC Mill that has the capacity for
the machining required While porting and relieving the heads needs a multi-axis mill such
operations can be avoided in favor of editing an existing head unit or making a unit from
scratch to our own capabilities The goal would be to limit machining time to less than 50 hours
of machining
During the assembly phase attention to tolerances is of utmost importance to maintain
the best possible quality and a high life cycle for the unit At this point the cost of miscellaneous
parts comes into play with the correct application of the proper bearings fasteners and other
part sizes This is of course with consideration for part standardization and cost minimization
Testing amp Tuning
This phase will include the optimization of power output and fuel consumption The
facilities available allow us to digitally monitor many aspects of the engine while it is running
By analyzing the collected data the system can be changed accordingly whether it be the
ignition timing compression ratios or valve moment among many other options From the
results we can obtain proper comparisons between the new forced induction system and a
naturally aspirated system
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
A generalized model can be obtained via the experimental head unit purchased for the
experiment From there modifications can be added in the 3D program in order to include a
forced induction system Everything from the bearings to the fasteners can be modeled and
accounted for in a final bill of materials
By the iteration process the design would be continuously improved in order to keep it
as simple as possible to machine and assemble The Finite Element Analysis tools can be used to
analyze forces applied to the assembly Other programs such as Genesis can find material that
isnt supporting a load and can therefore be optimized for necessary strength and minimizing
the overall product weight It will also be designed to minimize the number of custom parts
that need to be made in favor for parts available for purchasing The overall goal is to keep
manufacturing costs down and maximize the efficiency of the unit
When the final assembly is complete and ready to be prepped for machining a
complete drawing package can be created for every individual custom part that is to be
manufactured as well as accounting for all the necessary fasteners bearings and other
miscellaneous parts that used for incorporating forced induction
Machining amp Assembly
This section will be the most labor intensive section of the process As much coding is
needed to set up such a relatively complicated part not to mention the time it takes to machine
the parts themselves However the University of Idaho has a CNC Mill that has the capacity for
the machining required While porting and relieving the heads needs a multi-axis mill such
operations can be avoided in favor of editing an existing head unit or making a unit from
scratch to our own capabilities The goal would be to limit machining time to less than 50 hours
of machining
During the assembly phase attention to tolerances is of utmost importance to maintain
the best possible quality and a high life cycle for the unit At this point the cost of miscellaneous
parts comes into play with the correct application of the proper bearings fasteners and other
part sizes This is of course with consideration for part standardization and cost minimization
Testing amp Tuning
This phase will include the optimization of power output and fuel consumption The
facilities available allow us to digitally monitor many aspects of the engine while it is running
By analyzing the collected data the system can be changed accordingly whether it be the
ignition timing compression ratios or valve moment among many other options From the
results we can obtain proper comparisons between the new forced induction system and a
naturally aspirated system
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
Timeline
Time Span 1 Academic year
August to Mid-October
CAD Prototyping Due to the complexity of the model a significant amount of time
would be needed to properly account for all processes involved in both a cylinder head and a
forced induction system Sufficient documentation would also be covered in this period in order
to purchase parts early Purchased parts tolerancing would then be taken into account to adjust
for differing dimensions from ideal sizes to actual sizes in reality
Mid-October to Late February
Machining and Assembly The process of machining should always be overestimated in
order to account for discontinuities in a weekly routine Such things include tooling and coding
prep daily setup and cleanup for each day and accounting for any possible machining errors
and parts to be remade In my experience this is always needed because sooner or later
something will get messed up and will need re-machining And any extra time found would be
used to ensure the best quality is put into the product
Beginning of March to May
Test amp Tune Once the prototype is completed and ready to be tested the assembly will
be fitted to an existing system (ie the lower engine block provided on the purchased unit) to
be fitted to a Dyno machine in which power rpms and other critical values can be obtained
and recorded for later evaluation All equipment mentioned is already owned by the University
and therefore doesnt need to be purchased Two months would be deemed necessary as to
test the unit and conduct any improvements that can be implemented for the final product
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
Additional Information
Institutional Resources Available
The University of Idaho has every large piece of equipment needed for this whole research
project all of which is in the Gauss Johnson Building here on campus First is a high tech CAD lab with
Catia and other programs available for use It also has a machine shop that is more than competent for
the task of machining and assembling a prototype via computer navigation controlled (CNC) end mill and
lathe In the same building there is also an engine testing bay with the equipment needed to obtain a
full analysis
Dissemination Plan
As a tangible product will be the result of this research direct marketing on the Universitys
behalf is a tangible option A patent could be easily obtained for the product and licensed out by the
University to external companies The first and foremost presentation would be at the Senior Design
expo in the spring to showcase our product and our findings
Regulatory Committee Approval
This project requires no controlled substances In fact the only substances needed are
commonly purchased at an automotive shop or gas station Safety measures are currently in place to
ensure the utmost safety of personnel and the environment during this operation However since no
substance needed in this operation are considered controlled there is no need for regulatory approval
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19
Sources Cited
51 BorgWarner turbo history Turbodrivencom Retrieved 2010-08-02
52 [Cengle YA amp Boles MA (2008) Thermodynamics An Engineering Approach 6th ed New York
NY McGraw-Hill]Page 70 590
53 Obama CAFE increase to national standard of 355mpg by 2016 autoblogcom Retrieved 2009shy
05-19