Integration of a Turbocharged Engine in a Formula SAE Car

This project concerns Minnesota State Mankato\u27s entry in the Formula SAE competition. Formula SAE is a contest where 130 student teams from around the world design and build formula style race cars, and then compete for top honors. Included in this presentation is the near completed car, including selected engine, fabricated engine components, selected turbocharger, production cost, weight reduction, methods of engineering and modification results. The engine team focused efforts on a 2001 Honda F4i engine, mated to an IHIRHF4 turbocharger. A specialized intake and restrictor (required by FSAE rules) was designed in Pro/E cad software and built by Stratysis specifically for this application out of Polyphenylsulfone, a polymer with special mechanical and chemical characteristics. The engine was modified to run on E-85, and custom camshaft profiles were determined using Dynomation Engine Simulator. The engine was then tuned and tested to determine the affects of different intake designs and to test the actual results of different camshafts on a Superflow engine dynamometer. Also tested were torque and horsepower outputs as well as noise levels