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Home Tutorials Shape Optimisation of a FSAE Car Airbox

Tutorial 3: shape optimisation of a FSAE car airbox

This tutorial shows how RBF Morph can be used for the optimization of an engine component. The airbox of a FSAE is built using flat metallic sheets (a cheap manufacturing solution). However even for a simple design mass flow balancing is a concern; for this reason several shapes have been investigated to find the optimal layout for maximizing mass-flow with uniform charging of the cylinders.

The aim of this tutorial is to study the effect of cube position and attitude angle, first as individual solutions and then combining them.

Step 1: looking for a new shape.

In this step the the original shape of airbox is used as the starting shape. Three preloaded solutions are first explored showing source points arrangements. The first uses only points on surface to change the width; the second uses two moving cylinders to force a symmetric movements of the edges on the throttle side and points on surfaces to preserve other parts; the third is based only on points on surfaces to change the depth of the box imposing a rigid movement to all the parts on the throttle side.
A DOE file (previously generated thanks to the DOE tool of RBF Morph 1.2) is then loaded to preview the combination of the three solutions.

Step 2: refining the new shape

In this step the the best shape resulting from Step 1 is taken as the starting point. The geometry is further modified to evaluate the effect of airbox depth and of the position of the lateral edges on the engine side. Two preloaded solutions are first explored showing source points arrangements. The first is based on three moving box: the first (side engine) is fixed; the second is scaled using the surface of the airbox at the engine side as the reference point; the third is moved accordingly to the same movement of the aribox surface on the throttle side. The second solution is similar to the one exposed in Step 1 of this tutorial (two moving cylinders). Also in this case a DOE file (previously generated thanks to the DOE tool of RBF Morph 1.2) is loaded to preview the combination of the two solutions.



 
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