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Heads Under Pressure

Heads Under Pressure. Snowmobile Head Design Team Members: Peter Britanyak, Nick Harker, and Chris Tockey. Deliverables. Head re-designed to accept pressure sensors for in-cylinder pressure data Research on whether casting the head is feasible and cost effective. Specifications.

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Heads Under Pressure

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  1. Heads Under Pressure Snowmobile Head Design Team Members: Peter Britanyak, Nick Harker, and Chris Tockey

  2. Deliverables • Head re-designed to accept pressure sensors for in-cylinder pressure data • Research on whether casting the head is feasible and cost effective

  3. Specifications • Pressure sensor to acquire in cylinder pressure data • Starting with the design used on the Evinrude outboard motor • Not responsible for data acquisition • Sparkplug • Shorter electrode (NGK) • 30º sparkplug angle from deck surface • Maintain current location • Injectors • Design injector seating as per email drawings • 9º injector spray angle towards intake side • Near nozzle geometry as per email drawings

  4. Combustion Chamber • No dome offset • Squish area same as turbo head 34% • Dome height approx. 1 inch as necessary for compression ratio • Dome angle needs to be determined for the correct compression ratio • Compression ratio of 6.5:1 • Dome radius .75 inches • Cone to plug distance is -.08 inches • Squish velocity of 15-20 m/s • Squish diameter of 1.95 inches • Squish radius from cone to squish .25 inches (double turbo head)

  5. Manufacturing • Research casting as a method to manufacture the head • Report on viability and cost • Obtain Head bolts long enough to prevent stripping and uphold aesthetics of motor

  6. Pressure Sensors • Contacted Kistler about part # 6052C Cost: $2500 each • Not part of our budget (from Karen) • There are detailed drawings available so the head can be designed without buying the sensor.

  7. Sparkplugs • From past experience NGK sparkplugs have been the most successful. • The aim was to use a plug with a shorter electrode to prevent it heating up and causing detonation at high revs. As of now we are still working on the decision of which sparkplug to use. • The challenge is finding the sparkplug that will allow for a plug to injector spray cone of -.08 in.

  8. Squish Velocities

  9. Squish Velocity Value Range

  10. Configuration 1

  11. Configuration 2

  12. Configuration 3

  13. Volume Comparison For Config. 3

  14. Plug to cone issue • Original Specs: • 9º injector angle • 14º cone angle • -0.08 in cone to plug distance • Modified specs: • 7-9º injector angle • 22º cone angle • Electrode touching fuel cone

  15. Injector Seating

  16. Casting • Contacted Eck Industries and D8 • Toured D8 facilities talked with owner about the possibility of casting: • $3-4k for pattern with approximately 4 week lead time • $100-200 per casting with approximately 1 week lead time • Contacted Travis Pattern and Foundry in Spokane. Minimum run of 50 or more. • Referred By Travis Foundry to Lost and Foundry • Sells casting equipment • Ability for in house casting • Setup Cost $400

  17. Pros: After initial investment, cheap and quick to make. Easy “quick” prototyping Casting knowledge and experience gained to team Easier to implement design changes with cast head blank Cons: Expensive initial cost Out of house (less control) Time to create first head Unknown design criteria Still requires machining of final surfaces Casting Pros and Cons

  18. Decision points • Pressure Sensor (6052C or other?) • Spark Plug type • Squish Velocity (Specific RPM or band?) • Combustion Chamber design • Plug to cone distance • Manufacturing (Casting)

  19. Current Budget • Plugs • $12 each • Manufacturing • Casting • D8 - $4000 initial + $200 per cast • Lost & Foundry (in house) - $400 • Machining • Material – Billet Aluminum $100? • Tooling – In house $100? • Bolts • ARP approximately $100 • Gaskets • Not yet researched - $100?

  20. Future Plans • July 10th Design Review • July 12th Sparkplugs ordered, pressure sensors chosen. Decide on manufacturing process. • June 17th First Iteration sent to Andy and Justin for review • June 24th Completed iteration sent to Andy and Justin for review • Aug 4th Design Finalized and ready for manufacture.

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