RPM&T Group
University of Warwick
Contents
• Introduction to Laser Sand Sintering
• Introduction to Warwick Formula Student
• Benefits / Limitations
Laser Sand Sintering
Laser Sand Sintering
• DirectCast process
– CAD file of part used to
design mould (cope, drag
and cores)
• Build volume of
720x380x380mm
• Design Aims
• Optimal mid-range torque
– Shape of plenum
– Volume of plenum
– Length of runners
– Shape of runners
Intake Design Development
• Design Aims
• Good throttle response
– Volume of plenum
Intake Design Development
• Design Aims
• High volumetric efficiency
– Plenum volume
– Plenum shape
– Cross-section of runners
– Alignment of restrictor,
plenum and runners
Intake Design Development
• Design Aims
• Even flow distribution
– Shape of plenum
– Alignment of plenum &
runners
Intake Design Development
• Design Aims
• Set-up flow field
• Plenum& runners
designed using 1-D
pressure simulation
software
– ‘Ricardo WAVE’
Intake Design Realisation
• Originally fabricated
from sheet and welded
• Many disadvantages
– Extensive lead-time
– Costly
– Non-optimal structure
• Lack stiffness and
breathe
• Require extensive
reinforcement
– Non-smooth flow due to
seams and alignment
– Design limited by
fabricator skill level
Intake Design Realisation
• Sand Casting has
revolutionised the
intake development
– Rapid design
realisation
– Complex design
realisation
– True to CAD
manufacture
Intake Design Realisation
• Supercharged intake
• 7 component mould
– Inlet and outlet
(2 mould halves each)
– Main plenum
(2 mould halves + core)
• Completed in 3 builds
– Cope
– Drag
– End moulds & core
Cost & Time
• 4 component mould
– Built in 2 halves
– 2 mould halves per plenum side
• Integrated core
• Integrated runner and gate
• Completed in 2 builds
– Side 1 cope & drag
– Side 2 cope & drag
• Non-optimal performance
– Edge seams restricted air flow
– Entry re-aligned to straighten flow
– Plenum and mould redesigned
Intake Design Realisation
• Normally aspirated intake
– Split line between top and bottom
• 4 component mould
– 2 mould halves for bottom
– 2 mould halves for top
• Completed in 2 builds
– Bottom cope & drag
– Top cope & drag
• Provided optimal performance
– Mid-range torque
– Throttle response
– Even flow distribution
Intake Design Realisation
• Runner
– Length altered to offer
higher mid-range torque
– Curvature adjusted to align
with top-fed plenum
• 3 part moulds
– Two mould halves & core
• Completed in 2 builds
– Cope x 4 + drag x 4
– Core x 4
Cost & Time
Dr Greg Gibbons
P: +44 24 7652 2524
F: +44 24 7652 4878
E: g.j.gibbons@warwick.ac.uk
www: http://www2.warwick.ac.uk/fac/sci/wmg/