This paper summarized the development methodology and technical experiences on Formula Student racecar engines acquired by Jilin University from 2011 to 2015. This series of engines are all based on 600cc 4-cylinder motorcycle gasoline engines and were modified to turbocharged engines which met the Formula Student technical regulations, in order to achieve higher power output, wider torque band as well as lower fuel consumption.
During the development process, multiple research projects have been conducted surrounding the turbocharging technology. These research projects have covered multiple areas including the matching of the flow rate characteristics of the engine and the turbocharger, the design of intake and exhaust systems, research on the wastegate as well as its actuator, the tuning and control of the boost pressure as well as the design of the lubrication system for the turbocharger, etc. The utilized research methods included 1D CFD engine performance analysis, 3D CFD fluid analysis as well as the engine dyno test.
The experiment and analysis results showed that, the developed engine, with the installation of a 20mm intake restrictor, was able to retain over 95% of the maximum power output of the stock engine while having a maximum torque output of 130% of the stock engine. In the meantime, the minimum BSFC at WOT was reduced by 15%. The turbocharger worked smoothly with the lubricant ideally sealed, all of which satisfied the comprehensive requirements of a Formula Student engine.