(Mahle)

The Integration of a Positive Displacement Supercharger with a Naturally Aspirated Engine

BEB801 Project Proposal

Aaron Palm | 07565887 | Supervisor - Dr Wim Dekkers Bachelor of Mechanical Engineering EN40 Faculty of Science and Engineering 2013

Queensland University of Technology

 1. Project Background ............................................................................................................... 3 2. Problem Statement ................................................................................................................ 3 3. Objectives ................................................................................................................................. 3 4. Tasks .......................................................................................................................................... 3 5. Project Plan .............................................................................................................................. 5 6. Literature Review .................................................................................................................. 6 References ........................................................................................................................................ 9 Bibliography .................................................................................................................................... 9

1. Project Background
This study will focus on the integration of a positive displacement supercharger to a naturally aspirated engine. The positive displacement supercharger increases the charge density of the working medium (air or air-fuel mixture) (Hiereth & Prenninger, 2007), by displacing a greater volume of the working medium into the work cylinder in comparison with a naturally aspirated engine. Furthermore, there are several elements that can have an adverse effect on the volumetric efficiency of an internal combustion engine. Such factors include the intake port geometry of the cylinder head, where the working medium is transferred from the end of the intake manifold to the work cylinder. The ports of a cylinder head are often tailored to increase the fluids mass within the working cylinder, while maintaining a satisfactory flow velocity through the port by manipulating the radii of the curves within the port and other geometric factors to overcome restrictions and optimise the volumetric efficiency of the cylinder head, while retaining specific geometries to promote the mixture of the working fluid.

2. Problem Statement

A naturally aspirated engine works on the principle where the pressure difference between the intake port and work cylinder draws air through the intake where the ports are tailored to obtain the greatest volumetric efficiency possible. Once the induction of the engine becomes forced by the means of a supercharger, the volumetric efficiency of the cylinder head decreases for the same port geometry. Therefore, the port geometries, once tailored to suit a naturally aspirated engine must be modified to suit the increase in flow rate and pressure. This study will take the cylinder head from a naturally aspirated WR450-F motorcycle engine, where the necessary port modifications will be carried out to suit the flow characteristics produced by an AMR-300 positive displacement roots blower.

3. Objectives
1. 2. 3. 4. 5.

Investigate the effect of working fluid charge density to mechanical power output Physically test the volumetric flow rate of the WR450-F cylinder head ports Study the computational fluid dynamics of the WR450-F cylinder head ports Modify the cylinder head port geometry to cater for an increase in flow rate Compare the modified cylinder head ports to the naturally aspirated

4. Tasks
1. Obtain texts and theoretical concepts on turbo machinery and four-stroke internal combustion engines 2. Using a flow bench, measure the flow of the WR450-F engine 3. Develop a computational model of the WR450-F ports using a 5-axis CNC probe/3- axis CNC/digitising arm 3

4. Refine computational model to replicate the WR450-F ports to within a set tolerance 5. Perform computational fluid dynamic (CFD) testing on the model 6. Modify computational model using CAD software, checking modifications using CFD analysis 7. Compare naturally aspirated ports to modified ports

5. Project Plan
Week 1 2 Start Date Task 25/02/2013 - Determine project title - Liaise with supervisor about topic - Source relative literature (books, articles, journals etc.) 11/03/2013 - Begin project proposal - Begin Library Research task 18/03/2013 - Liaise with supervisor about proposal and library resource task 25/03/2013 - Submit project proposal - Submit library resource task Mid-Semester Break 8/04/2013 - Source Flow Bench - Source Cylinder Head Port Scanner - Source WR-450F Cylinder Head 22/04/2012 - Finalise Flow Bench and Cylinder Head Port Scanner sources - Begin Progress Report 29/04/2013 - Determine requirements for flow bench testing - Write up Flow Bench Experiment Test Procedure - Perform Flow Bench Testing - Perform brief analysis of Flow Bench Test - Perform Cylinder Head Port Scanning - Continue Progress Report - Submit Progress Report END OF BEB801/BEGINNING OF BEB802 - Finalise Cylinder Head Port Scanning - Replicate intake port geometry using point cloud sourced from cylinder head port scan - Debug computational model - Define CFD Analysis Boundary Conditions - Setup CFD Model - Perform CFD Analysis - Modify Model - Perform further CFD Analysis - Continue until CFD Analysis results match experimental results - Modify Intake Port Geometry (Optimise) - Perform CFD Analysis - Compare both models - Optimise second model further if required

Planning

3 4 5 6 - 7 8 9

Testing

10 11 12 13 1 2 3 4

Computational Analysis

5 6

 7 - 8 9 10 11

- - - - - - - - - - - - - - - -

12 - 13

Begin data analysis Begin Final Report Write-up Continue Report Write-up Draw conclusions from analysis Finalise conclusions Continue Report Write-up MID-SEMESTER BREAK Define Implications Finalise Report Draft Proof Read Report Refine Report Begin dissemination of project Finalise dissemination of project Proof Read Report Refine Report Finalise Report Submit Report

Report Write Up

6. Literature Review
The internal combustion engine produces a power output by transforming the chemical energy stored within fuel to heat energy. This transformation occurs by combusting the fuel, in conjunction with oxygen extracted from the air mass within the work cylinder. This heat energy acts on a piston that drives a slider-crank linkage, which successively transforms the heat energy into mechanical energy. Furthermore, the power output of the engine depends on the amount of air within the cylinder. This air quantity is related to the mass of air within the work cylinder rather than the cylinder volume, the air mass will depict the fuel mass introduced to the work cylinder. Where the mass of the air is quantified by the following relationship, !"# = !"# !"#$% Furthermore, since the Vcyl is constant, the mass of the air can be used to approximate the charge density of the air (Hiereth & Prenninger, 2007). Furthermore, the heat energy added to the work cylinder can be quantified by the following, !"" =
!!"# !!"#$% !!"# !!"#

1 (Hiereth & Prenninger, 2007)

Where Qlow is the calorific value of fuel, which quantifies the amount of potential chemical energy that can be transformed into heat energy with complete combustion. Furthermore, the minimum air requirement for combustion is numerically defined by the factor Amin, where is the density of the working fluid, Vcyl is the volume of the working cylinder. 6

Furthermore, with the assumption that the calorific value of the fuel and the minimum air requirement remain constant, the heat energy acting on the piston is directly proportional to the air density (Hiereth & Prenninger, 2007), !"" ! ,!"# Furthermore, the indicated mean effective pressure (IMEP) is the average pressure that acts across the surface area of top of the piston. Furthermore, this is quantified by the following equation. !"" = ! !"# Therefore, by substituting this into the equation (1), !"# !"#$% !"# ! !"# = !"# By sustaining the former assumptions, with the additional assumption that there are no losses in the combustion process, subsequently the indicated efficiency (i) is 100%, the following may be stated, ~ !"#$% Therefore, the density of the air within the cylinder has a direct influence on the indicated mean effective pressure. To increase the density of the air charge at the conclusion of the intake stroke, air pumps, or more commonly known as superchargers are used in conjunction with the engine. There are three finite groups of supercharging, one of them being supercharging by gas energy recovery air pumps. This form of supercharging is where the exhaust from the engine is fed directly into a centrifugal turbine, which successively rotates a centrifugal compressor impeller through a common shaft. This, in effect compounds the intake working fluid, thus increasing the volumetric flow rate and pressure of the fluid. The second common type of supercharging is by the means of a mechanical drive. Similar to the gas energy recovery air pumps, the mechanically driven air pump alters the flow characteristics of the intake working fluid, however the centrifugal turbine is replaced with a pulley system that uses the mechanical work output from the engine to drive the air pump. Furthermore, these air pumps can either be centrifugal compressor or a positive displacement air pump, where the flow characteristics produced by each pump type prove beneficial for several applications. In conjunction with these two forms of supercharging, the working fluid may also be charged by the means of gas-dynamic effects. Such effects include the exploitation of pressure waves within the intake and exhaust system (Hiereth & Prenninger, 2007). Such concepts can be turned into practice by tuning the length of exhaust and intake runners in respect to the valve timing of the engine. 7

Passing the working fluid from the predeceasing intake system to the working cylinder is the intake port within the cylinder head. The geometry of such a passageway controls the flow of the working fluid and is tailored to increase the fluids mass within the working cylinder, while maintaining a satisfactory flow velocity through the port. This is achieved by eliminating geometries that induce eddying flow thus sustaining the continuity of flow, in turn increasing the Cf (flow coefficient), consequently improving the volumetric efficiency. In confliction, the intake port also defines the in-cylinder air motion (Son, Lee, Han, & Kim, 2004), where the working fluid is manipulated, in turn producing swirl or tumble to promote mixture of the working fluid, subsequently aiding the completion of combustion. Furthermore, both concepts, although conflicting, have a great effect on the mechanical power output of the engine. Therefore the flow continuity must be maximised while maintaining a satisfactory level of fluid motion within cylinder.

References
Burgess, P., & Gollan, D. (2006). How to build, modify & power tune cylinder heads. Dorchester, England: Veloce. Chapdelaine, N. (1998, June 1). From Art to Port. Manufacturing Engineering , p. 120. Hiereth, H., & Prenninger, P. (2007). Charging the Internal Combustion Engine. Wien: SpringerWienNewYork. Mahle. Mahle Valvetrain Systems Key Visual 2. -. Mahle Group, -. Son, J.-W., Lee, S., Han, B., & Kim, W. (2004). A Correlation Between Re-Defined Design Parameters and Flow Coefficients or SI Engine Intake Ports, SAE Technical Paper 2004-01- 0998. Hyandi Motor Company, Power-train R&D Centre. Detroit: SAE International.

Bibliography

Blair, G. P. (1999). Design and simulation of four-stroke engines. Warrendale, P: Society of Automotive Engineers. Smith, E. J. (2008). Let it flow: A look at cylinder heads. National Dragster, 49(35), 74-76. Retrieved from http://search.proquest.com/docview/198049852?accountid=13380 Selvaraj, B., Sridhara, S., Indraprakash, G., Senthilkumar, A. (2011). Effects of Intake Port Geometry on the Performance of an SI Engine Adomeit, P., Jakob, M., Pischinger, S., Brunn, A. (January, 2011) Effect of Intake Port Design on the Flow Field Stability of a Gasoline DI Engine, SAE Technical Paper 2011-01-1284, 2011 Vizard, D. (1973). Theory and Practice of Cylinder Head Modification. Brentford, Middx: Interauto Book Company