Student Grant Proposal by Eric Sprague

STUDENT GRANT PROGRAM Investigator Information Form PRINCIPAL INVESTIGATOR: Name: Eric Sprague

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Email : spra0272@vandals.uidaho.edu Phone: 208-994-1564

VandallD: 081-36997 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: Depa rtment:

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ELIGIBILITY FOR STUDENT GRANT PROGRAM:

[!J Undergraduate Graduate

Office: Phone:

D Law

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[!] Full Time Student

:J Moscow Campus

ARE YOU A FIRST-TIME INVESTIGATOR?

,I Yes

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:

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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.

RECOMMENDED EXTERNAL REVIEWERS:

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#2 Student Name:

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Project Type:

Yes

C Basic Research

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Click on title for more information

Explanation

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Are Human Subjects Involved? Assurance#

Date:

Are Experimental Animals Involved? Protocol#

Date:

-... .. ... Are Biohazards, Recombinant DNA, or

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Radiation Involved? Approval Date:

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Are Select Agents or High Consequence Livestock Pathogens and Toxins Involved?

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Applied Research

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Is proposal subject to Export Controls or Re-Export?

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D Instruction

Name:

STUDENT GRANT PROGRA'M Project Grant Budget Form " t ("t . d) EqUlpmen I emlze

Please fill out this form usning Adobe Acrobat

Student 10 #:

Eric Sprague

081-36997

for all expenses listed under " EquipOlent" indicate on page 2 of tl, is PDf who will aSSUOle responsibility for the equipOlent once t he project has been completed .

Amount

1. Used 4cl Engine or Running 4cl Motorcycle

$2000

$0.00

Equipment total: _$_20_0_0_ __ Materials and Supplies (itemized) 1. Aluminum Stock

$300

2. Miscellaneous Parts

$700

3. Tooling materials

$100

$0.00

Materials and supplies total: _$_1_00_0_ __ Travet Costs (itemized) 1. List items Here

$0.00

Travel total: $0.00 ---足

Personnel/Services (itemized) 1. Master Machinist Assistance

$1600

$0.00

Personnel/services total: _$_0_.0_0_ __ Other Expenses (item ized)

All items listed under "Other Expenses" must be accompanied by a justification statement on the 2 page of this PDf.

1. List Items Here .........

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Other total : $0 .00

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Subtotal: $4600 ----Facilities and Administrative Costs (8 0/0): _$_36_8_ __ Your Current Total: Total must NOT EXCEED $5000.00

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Total Request: _$4_9_68_ _

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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:

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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:

Who will assume responsibility for the equipment once the project has been completed?

I Justification for expense if over $100 :

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:

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Number:

Justification for expense if over $100: ----------------------------------------------------~

Personnel/Services (itemized)

For all expenses over $100.

Justification for expense:

Number:

Machinist, Russ Porter, is an invaluable resource. He is constantly giving insi~t-to better ] IrThe Masterthrough economy and ingenuity. Whatever the University pays him, its not enough. The I ~c~chining ~ imates

are based on above average machinist pay at about 80 hours of contribution.

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Justification for expense:

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Other Expenses (itemized) Number:

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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 university's 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 & 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 & 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 isn't 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 & 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 & 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 & Tune: Once the prototype is completed and ready to be tested, the assembly will be fitted to an existing system (i.e. 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 doesn't 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 University's 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". Turbodriven.com. Retrieved 2010-08-02. 52: [Cengle, YA, & Boles, M.A. (2008). Thermodynamics: An Engineering Approach. 6th ed. New York, N.Y.: McGraw-Hill.],Page 70, 590. 53: "Obama: CAFE increase to national standard of 35.5mpg by 2016". autoblog.com. Retrieved 2009足 05-19.