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Design of a 4-Cylinder Gasoline Turbo Engine Intake Manifold

[+] Author Affiliations
Guangwu Tang, Bin Wu, Yuchao Chen, Xiang Liu, Armin K. Silaen, Chenn Q. Zhou

Purdue University Northwest, Hammond, IN

Di Wang

SAIC Motor Commercial Vehicle Technical Center, Shanghai, China

Paper No. IMECE2016-67125, pp. V009T12A019; 6 pages
doi:10.1115/IMECE2016-67125
From:
  • ASME 2016 International Mechanical Engineering Congress and Exposition
  • Volume 9: Mechanics of Solids, Structures and Fluids; NDE, Diagnosis, and Prognosis
  • Phoenix, Arizona, USA, November 11–17, 2016
  • Conference Sponsors: ASME
  • ISBN: 978-0-7918-5063-3
  • Copyright © 2016 by ASME

abstract

A redesign of the intake manifold on a turbo engine transformed from naturally-aspirated engine was conducted. A new intake manifold geometry was proposed to meet both the flow uniformity and structural strength requirements. Additionally, the new intake manifold design has to meet power and torque performance requirements. In order to perform this study, a systematic design methodology was proposed. One-dimensional characteristic analysis was firstly conducted using the commercial software GT-Power, by which the intake manifold length and the pressure stabilizing cavity volume were determined. The results indicate that the intake manifold length and the pressure stabilizing cavity volume have limited effect on the engine performance. Next, the commercial computational fluid dynamics (CFD) software ANSYS Fluent was utilized to simulate the flow characteristics inside the intake manifold to investigate the flow uniformity and the pressure drop. With the newly designed geometry for the intake manifold, the maximum flow uniformity coefficient is 1.83%. This is lower than the standard requirement of 3%. Due to the fact that the intake manifold for the turbo engine will experience larger pressure than the original naturally-aspirated engine, the strength and the mode frequency of the new intake manifold design were verified by using the commercial finite element analysis (FEA) software Abaqus. The maximum stresses at internal and external of intake manifold structure were 110 MPa and 93 MPa respectively, which are lower than the yield strength. Additionally, the frequencies of the first mode and second mode are 159.87 Hz and 237.10 Hz respectively, which indicates that a physical support may be needed. This comprehensive design methodology will ensure the performance of an intake manifold design for a turbo engine transformed from a naturally-aspirated engine is met.

Copyright © 2016 by ASME

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