The below project was a group project of 3 members. All work indicated below are my own and individual contribution.
Project Objective
The project was based on a proof-of-concept design. The objective – to propose a novel & effective lubrication mechanism for Rotary Wankel Engines that replaces net loss lubrication methods.
Proposed design
It was decided that we would utilize the centrifugal forces present in the crank interface to channel lubricant (highlighted in green in the image below) to the apex seals. My team member’s studies focused on determining the effects & our requirements in terms of chamber pressures, fluid flow, oil film thickness & viscosity.
My key responsibilities in the group project was the CAD & manufacturing of the working prototype.
CAD
Based on a 1:1 scale of the Mazda 13B Rotary Engine, my task was to build a moving prototype to simulate the lubrication on the rotor housing of a Rotary engine.
To minimize cost, we opted to prototype a single rotor, and for demonstration purposes, we required a transparent face to view the internal lubrication.
The video below and subsequent images show the assembly & CAD.
Manufacturing
Given my responsibilities & the time allocated to my Formula Student team, only 3 days (a weekend) was available to procure, machine, assemble & test the prototype.
It was a rather fun challenge, working all night at the CNC workshop, and completing the entire project on a budget less than £600.
