Development of Air Intake Manifold Using Alternate Materials by CFD Analysis

Abstract

Vehicle with high speed is in demand these days. This results in various types of high stresses in multiple vehicular components which may ultimately lead to engine failure and loss in fuel economy. Following the demand, the main objective of the present paper is to increase the performance and volumetric efficiency of the engine by using the lightweight alternate material. However, in order to bring the advantages of alternate material into play, many issues including static burst, noise, and vibration need to be settled in its design and development phase itself. The temperature mapping is carried out for air intake manifold and air duct to ensure that they withstand the temperature. Moreover, the flow analysis with respect to the mass flow rate of exhaust gas recirculation (EGR) is done followed by vibration measurement for alternate material polyamide 6 with glass fiber of 30%. Of all the above, the greatest challenge the paper investigates vests with achieving the volumetric efficiency of the engine similar or better to that of the aluminum manifold. To maintain or improve the volumetric efficiency, the plenum and runner volume are to be considered in such a way that the actual charge of air entering the cylinder through manifold is more effective and smooth.