This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Design and optimization of the intake system of a Formula SAE race engine
ISSN: 0148-7191, e-ISSN: 2688-3627
Published January 13, 2020 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
Several motorsport competitions impose restrictions on intake systems to limit maximum engine power. Since the restriction interferes with the efficiency of the intake system as a whole, it is necessary to study ways to minimize the negative effect of changes in engine performance. In practice, the regulation imposes restrictions to the inlet air which motivates the search for the minimum pressure loss in the restrictor while maintaining an equal volumetric efficiency between the cylinders. This way, it is necessary to tune the duct lengths and diameters, and plenum volume to obtain the maximum volumetric efficiency in the most required speeds. Formula SAE competition imposes an intake system restriction of 20 mm or 19 mm diameter (for gasoline or ethanol fueled engines, respectively). Thus, to reduce pressure loss in the imposed restriction orifice, a system with a convergent divergent duct forming a venturi tube was used. This venturi was designed to maximize its discharge coefficient to increase engine volumetric efficiency. Considering that the focus of motorsport competitions is performance, this paper presents a method to minimize intake system restriction which interfere on engine performance. GT-Suite software was used to create an engine thermodynamic model, with focus on the optimization tool for DoE (Design os Experiment). The results of this study showed a considerable increase on the volumetric efficiency between 6000 rpm and 10000 rpm for the proposed four cylinder 0.6 liter engine. Consequently, increase on torque and power were also obtained. Thus, the maximum torque developed in chassis dynamometer reached 5.8kgfm and the maximum power in 76HP, which represents an increase of 1.8% on torque and 22.21% on power compared to the previous designed intake system.
- Pedro Carvalho - Federal University of Santa Maria
- Alexandre Piccini - Federal University of Santa Maria
- Aleff Goulart - Federal University of Santa Maria
- Felipe Balbom - Federal University of Santa Maria
- Alice Müller - Federal University of Santa Maria
- Thompson Lanzanova - Federal University of Santa Maria
- Mario Martins - Federal University of Santa Maria
CitationCarvalho, P., Piccini, A., Goulart, A., Balbom, F. et al., "Design and optimization of the intake system of a Formula SAE race engine," SAE Technical Paper 2019-36-0253, 2020, https://doi.org/10.4271/2019-36-0253.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
- Heywood, J.B. , Internal Combustion Engine Fundamentals, McGraw-Hill, 1988.
- Gamma Technologies . “GT-SUITE (Version 7.3) Performance manual”, Westmont, IL, 2013.
- Blair, Gordon P. 1999. Design And Simulation Of Four-Stroke Engines. 1st ed. Warrendale, PA: Society of Automotive Engineers.
- N. W. Sung, J. S. Choi, and Y. I. Jeong, “A Study on the Flow in the Engine Intake System,” SAE Tech. Pap. Ser., vol. 1, no. 412, 2010.
- J. Vaz, A. R. Machado, R. K. Martinuzzi, and M. E. S. Martins, “Design and Manufacture of a Formula SAE Variable Intake Manifold,” SAE Tech. Pap. Ser., vol. 1, 2018.
- D. N. Malkhede and H. Khalane, “Maximizing Volumetric Efficiency of IC Engine through Intake Manifold Tuning,” SAE Tech. Pap. Ser., vol. 1, 2015.
- L. O. F. T. Alves, M. G. D. dos Santos, A. B. Urquiza, J. H. Guerrero, J. C. de Lira, and V. Abramchuk, “Design of a New Intake Manifold of a Single Cylinder Engine with Three Stages,” in SAE Technical Paper Series, 2018, vol. 1.
- D. B. Pai, H. S. Singh, and P. V. F. Muhammed, “Simulation Based Approach for Optimization of Intake Manifold,” SAE Tech. Pap. Ser., vol. 1, 2011.
- L. J. Hamilton and J. E. Lee, “The Effects of Intake Plenum Volume on the Performance of a Small Normally Aspirated Restricted Engine,” SAE Int. J. Engines, vol. 1, no. 1, pp. 1312-1318, 2010.
- M. A. Ceviz , “Intake plenum volume and its influence on the engine performance, cyclic variability and emissions,” Energy Convers. Manag., vol. 48, no. 3, pp. 961-966, Mar. 2007.
- SAE International , "2017 2018 Formula SAE Rules," https://www.fsaeonline.com/content/2017-s18%20FSAE%20Rules%209.2.16a.pdf,access in July 2018
- B. Jawad, K. Yee, S. Arslan, and L. Liu, “Improving Engine Performance Through Intake Design,” SAE Tech. Pap. Ser., vol. 1, 2013.
- A. Vaughan and G. J. Delagrammatikas, “Variable Runner Length Intake Manifold Design: An Interim Progress Report,” SAE Tech. Pap. Ser., vol. 1, 2010.
- A. Vaughan and G. J. Delagrammatikas, “A High Performance, Continuously Variable Engine Intake Manifold,” SAE Tech. Pap. Ser., vol. 1, 2011.
- R. H. Mckee et al., “PAPER SERIES SAE 2006-32-0070 JSAE 20066570 Experimental Optimisation of Manifold and Camshaft Geometries for a Restricted 600cc Four-Cylinder Four-Stroke Engine,” no. 724, 2006.
- ABNT , “NBR ISO 5167-1 Medição de vazão de fluidos por meio de instrumentos de pressão - Parte 1: Placas de orifício, bocais e tubos de Venturi instalados em seção transversal circular de condutos forçados,” 1994.