Design portfolio

1. ENGINEERING DESIGN
PORTFOLIO
By
Shivam Gupta

2. DESIGN AND ANALYSIS OF
INTAKE MANIFOLD & FUEL SYSTEM
Project Aim:
 To design, analyze, manufacture and physically test Intake Manifold & Fuel System for Formula Style
Race Car
Project Goals:
 To improve engine performance through dynamometer testing and on-track testing
 To reduce overall weight, make a reliable and efficient system
 To ensure that it can be easily manufactured, easy replacement and indigenize parts to lower cost.
 To conduct data acquisition for future use.
Software Used:
 Designing: CATIA, Solidworks, AutoCAD
 Analysis: ANSYS Mechanical & Fluent, Ricardo WAVE

3. DESIGN DECISION REASON
Material : Utem,
Durfaform
Easy availability, cheap and good
machinability
Basic shape
Convergent-Divergent type nozzle
ID:35mm
Throat Diar:20mm
OD:56mm
Convergent length:55mm
Divergent Length:175mm
Analysis techniques:
Analysis was conducted in fluent with a
target to achieve maximum static pressure
and reduce turbulence.
Manufacturing Fused Deposition Modeling, 3D Printing
DESIGN DECISION REASON
Material : Utem, Duraform
The material is selected as it can be
readily used for rapid prototyping
Basic shape
The intake runners were curved to
create a more compact system and
to clear the rules for the new
chassis.
The injector housing was integrated
into the runners for further space
optimization.
Manufacturing Fused Deposition Modeling
DESIGN DECISION REASON
Material : Utem
The material is selected as it can be readily used for
rapid prototyping.
Basic shape
Log type plenum with tangential entry to conserve
momentum.
Plenum Volume of 2.8L increased from 2.4L to reduce
starvation.
Flush type bell mouths to reduce formation of vacuum
pockets and increase air flow to engine cylinders.
Analysis techniques
Based on throttle response. In the initial design a
throttle change of 10% led to starvation, so volume was
changed so as to avoid starvation and maintain throttle
response.
Manufacturing It will be manufactured by Fused Deposition Modeling.
(Top to Bottom: Below are the Flow Simulations & Design Decisions of entire Intake Assembly simulated in Ricardo WAVE)

4. (Left to Right: Below are the rendered images & 2D drawings of Air Filter, Restrictor & Throttle Body Assembly
designed using CATIA and AutoCAD software)

5. (Left to Right: Below are the rendered images and 2D drawings of Upper Plenum, Lower Plenum, Runners & Fuel System
Assembly designed using CATIA and AutoCAD software)

6. Below is the rendered image of Intake and
Fuel Assembly designed using CATIA software
Air Filter
Upper & Lower Plenum
Restrictor
Throttle Body
Runners & Fuel System
Below is the rendered image of Intake Assembly on
Honda Engine’s model designed using CATIA software
Below are the rendered images of Assembly & Honda Engine’s
model on Vehicle’s Frame designed using CATIA software

7. (Left to Right: Below are the images of entire Engine Assembly mounted on the car while testing it on Dynamometer & on race
track)

8. DESIGN AND ANALYSIS (FEA) OF A PLANETARY GEARBOX
Project Aim:
 To Design Model and Analyze by varying different Gear Designing Variables for Epicyclic gear train (with
all its components) for a particular power input and material.
Software Used:
 Designing: CATIA, Solidworks
 Analysis: ANSYS Mechanical, MATLAB
Design Approach:
 Dimensions of the Sun, Ring & Planet gears, input and output power shaft were calculated.
 Load calculations were done on MATLAB software using Lewis equation & other gear designing
equations so that the system has sufficient strength to avoid failure under static or dynamic loading
during normal running conditions.
 Material for the Gears:

9. Design Approach (2nd Method):
 Using almost design method but different Parameters equations, six points are
calculated. (Refer bottom images shows final sketch generated using these
equations and points).
#z t x y
Point 1 0 14.232 0
Point 2 0.05 14.406 0.018
Point 3 0.01 14.917 0.146
Point 4 0.15 15.725 0.484
Point 5 0.2 16.77 1.131
Point 6 0.25 17.967 2.16
𝑥 = 𝑟𝑏 ∗ cos 𝑡 ∗ 𝜋 ∗ 1𝑟𝑎𝑑 + sin 𝑡 ∗ 𝜋 ∗ 1𝑟𝑎𝑑 ∗ 𝑡 ∗ 𝜋
𝑦 = 𝑟𝑏 ∗ sin 𝑡 ∗ 𝜋 ∗ 1𝑟𝑎𝑑 − cos 𝑡 ∗ 𝜋 ∗ 1𝑟𝑎𝑑 ∗ 𝑡 ∗ 𝜋
Below is the rendered image of Gear Profile obtained
using circular pattern using CATIA software
Below is the rendered image of Gear extruded using
Rib Feature in CATIA software

10. Rendered images of few more parts used in the Assembly
made using CATIA software

11. Above & below are the rendered images of Exploded
view of Planet Gear Assembly in CATIA software
Above & below are the rendered images of Exploded
view of Output Assembly in CATIA software
Above & below are the rendered images of Exploded
view of Input Assembly in CATIA software

12. TEAM 5
Above are the rendered images of Exploded view of Entire Assembly in CATIA software
Total Number of Components 97

13. Finite Elements Analysis of Components on ANSYS Mechanical
Below is image of Contact feature applied between the Planet gear and
the Ring gear
Below is image of Contact feature applied between the Sun Gear and the 3
Planet Gears. Contact type is indicated as Frictional Contact
Below is image of Supports feature applied to the different geometric parts &
Moment that is applied to the Sun gear
Below is image of Constrains applied on the Gear system including the Gravitation
force of 1- G

14. Below is image of Mesh of the Gear system with a
relevance of - 5
Below is image of Results for the Total deformation with Max Deformation
occurring at the Sun gear teeth
Below is image of : Results of the 1-G Stresses on the Gear
system
Below is image of Results for the Equivalent Von-Mises Stresses of the Sun gear

15. THANK YOU 