MIE.24 – Design, Optimization, and Computational Validation of a High Performance Exhaust Package for an FSAE Race Vehicle

• Eduardo Baez
• Ted Bulbuc
• Sebastian De Diego
• Andrzej Dlugopolski
• Jovan Munsamy

The exhaust manifold is a key component in the engine’s performance by optimizing gas flow from the combustion process. Our objective is to design and tune the manifold to act as a dynamic air flow pump, optimizing exhaust flow within specific RPM parameters. This project is specifically designed for the Formula Society of Automotive Engineers (FSAE) racecar, which competes in various design competitions. By collaborating with our team sponsor, the team will need to meet specific performance objectives, while aligning with specific design rules outlined in the FSAE rulebook. The project’s goal is to increase torque output in lower revolutions per minute (RPM), improve packaging, and create ease of future design iterations. Many different design iterations were considered and simulated, which includes material selection, and validations were performed to justify the performance of the manifold. Additionally, much consideration went into the safety of the component, as the nature of this critical powertrain system experiences high thermal loads and cycles. Furthermore, fluid dynamics simulations were conducted to analyze gas flow behavior and optimize the manifold’s geometry for enhanced performance across the desired RPM range. This presentation outlines the design methodology, testing procedures, and manufacturing processes involved in creating the exhaust manifold.