Design and Optimization of a Performance Muffler for a Formula SAE Vehicle

The combustion occurring in an internal combustion engine subsequently emits a high-intensity acoustic pulse along with exhaust gas flow. Formula SAE competition is imposing restrictions on acoustic emissions from an engine, which necessitates the activity of design and optimization of a high-performance muffler. The muffler has to be designed with the objectives of satisfying acoustic emission norms imposed and strategically designed to have less obstruction to exhaust flow and be lightweight to maintain the integrity of a Formula Student car. A novel approach of combining the effect of adsorptive and resonating muffler design has been inculcated in this work after the estimation of muffler size and resonance. The acoustic pressure analysis and exhaust flow efficiency are carried out using Ricardo Wave. These simulation results are validated with the developed prototype. The developed prototype is ascertained to fulfill the requirement of acoustic emission norms (103 dBC-110 dBC) without much compromise on exhaust flow efficiency.