IJIRST International Journal for Innovative Research in Science & Technology| Volume 2 | Issue 12 | May 2016

ISSN (online): 2349-6010

Review on Design of Intake Manifold For A

Formula SAE Car
Nimesh Shukla
PG Student
Department of Mechanical Engineering
CSPIT Changa

Kalpesh Vaghela
Assistant Professor
Department of Automobile Engineering
GEC Modasa

Anand Patel
Assistant Professor
Department of Mechanical Engineering
CSPIT Changa

Abstract
This review paper contains the basic concept of intake manifold. Intake manifold is the breathing system of the car engine which
supplies air to the engine cylinders where the combustion of the fuel occurs. The review paper contain SAE is the society of
automotive engineers which is working for the automotive industry, educators and students. SAE India organizes formula student
car racing championship name SUPRA every year. In this event a team of students has to follow all rules and regulations provided
in rulebook which is designed by SAE committee. This paper contains basic methodology and technology adopted for designing
intake manifold for 600 cc SUZUKI GSXR bike engine.
Keywords: Computational fluid dynamics (CFD), intake manifold, Plenum, restrictor, volumetric efficiency
_______________________________________________________________________________________________________
I.

INTRODUCTION

A research paper was published on Design of a new SI engine intake manifold with variable length plenum by M.A. Ceviz et al.
This paper investigates the effects of intake plenum length/volume on the performance characteristics of a spark-ignited engine
with electronically controlled fuel injectors. Previous work was carried out mainly on the engine with carburettor producing a
mixture desirable for combustion and dispatching the mixture to the intake manifold. The more stringent emission legislations
have driven engine development towards concepts based on electronic-controlled fuel injection rather than the use of carburettors.
In the engine with multipoint fuel injection system using electronically controlled fuel injectors has an intake manifold in which
only the air ows and, the fuel is injected onto the intake valve. Since the intake manifolds transport mainly air, the supercharging
effects of the variable length intake plenum will be different from carburetted engine. From the results of this study, the following
conclusions can be deduced:
The intake manifold plenum length/volume is highly effective on engine performance characteristics especially with the fuel
consumption parameters for SI engines with multipoint fuel injection system. The engine performance can be improved by using
continuously variable intake plenum length, Favorable effects of the variable length intake manifold plenum appeared at high load
and low engine speeds. Therefore, variable length intake manifold plenum is useful especially on urban and suburban areas (roads)
with the frequent stops and acceleration at starting conditions, It is necessary to determine the length of additional plenum
components for another engine and intake system with sensitive experimental studies.[1]
Analysis Of Change in intake manifold length and development of variable Intake system by Shrinath potul et al. Gas dynamics
of intake system plays a key role in deciding the performance of an engine. This dynamics are different for fuel injected and
carburetted engine and vary according to type of engine, number of cylinders, temperature at inlet, valve timing, valve angle and
other factors. Careful design of the manifolds enables the engineer (designer) to manipulate the characteristics to the desired level.
This paper investigates the effects of intake runner length on the performance characteristics of a four-stroke, single-cylinder sparkignited engine with electronically controlled fuel injector. In this paper basic intake tuning mechanisms were described. Engine
performance characteristics such as brake torque, brake power, brake mean effective pressure and specific fuel consumption were
taken into consideration and virtual simulation software LOTUS ENGINE SIMULATION was used to evaluate the effects of the
variation in the length of intake plenum on these parameters. It was found that change in runner length had a considerable effect
on the rpm at which peak value of torque was obtained (occurred). Accordingly a system to adjust the manifold length (tuned
adjustable intake pipe) was designed and developed. According to the simulation graphs, in order to increase the torque
performance, plenum length must be extended for low engine speeds and shortened as the engine speed increases.The paper
concluded the detailed study on generation of suction and compression waves was carried out and methods to obtain the maximum
use of these waves to improve engine performance were discussed. The effect of resonance of these waves and change in manifold
length on engine performance was analyzed mathematically and also using simulations. The engine performance can be increased
by using intake plenum length that can be varied continuously. It was found that the rpm at which peak torque occurred changed

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Review on Design of Intake Manifold For A Formula SAE Car

(IJIRST/ Volume 2 / Issue 12/ 023)

greatly with intake pipe length. As discussed above in order to increase the torque performance, plenum length must be extended
for low engine speeds and shortened as the engine speed increases. It was also concluded that for shorter plenum lengths the torque
curve was more flatter while as the length was increased the torque output curve peaked more and more. A proposed mechatronic
system was prototyped. Future work includes implementing this system on a engine and verifying results of practical, simulated
experimental system.[2]
Development of a new air intake and exhaust system for a single seat race car by Mr. Damein Kennedy et. al This paper deals
with the design, analyses and testing of a new air intake system for a single seat race car designed and manufactured by a team of
DIT students for the 2011 formula student competition in Silverstone. It also deals with the design, CFD analyses and noise
emission testing of a new exhaust system for the vehicle which is powered by a 600cc Suzuki GXR engine. The new air intake
system was developed to satisfy the rules of the formula student competition which required a 20mm restriction to be placed on
the air intake system. It was a requirement that all engine airflow passed through this restrictor. Implementation of the air restriction
also meant that a new engine map was required for effective operation of engine. This paper looks at a number of different
alternative air intake designs and compares the air flow simulations using CFD analyses. The use of rapid prototyping techniques
to produce a physical model is discussed. The design and manufacture of a new throttle body is also presented. The process for
engine remapping and dyno test results are also presented. The competition also required an exhaust system with noise emissions
below 110db. This paper presents the design and analyses of alternative exhaust paths and noise emission testing. Subsequent dyno
testing with the air intake also supported these conclusions. Physical testing however did highlight some issues with the strength
and rigidity of the ABS material used in the rapid prototype. Contraction of the walls of the intake system were visible due to the
vacuum created at high RPM. As the intake system was generated from a number of assemblies sealing the unit proved difficult.
It is recommended that a different manufacturing process be used eg carbon fibre or plastic moulding.[3]
Modeling and online parameter estimation of intake manifold in gasoline engines using sliding mode observer by Qarab Raza
Butt et al. Model based control of automotive engines for fuel economy and pollution minimization depends on accuracy of models
used. A number of mathematical models of automotive engine processes are available for this purpose but critical model parameters
are difficult to obtain and generalize. This paper presents a novel method of online estimation of discharge coefficient of throttle
body at the intake manifold of gasoline engines. The discharge coefficient is taken to be a varying parameter. Air mass ow across
the throttle body is a critical variable in maintaining a closer to stoichiometric air fuel ratio; which is necessary to minimize the
pollution contents in exhaust gases. The estimation method is based on sliding mode technique. A classical rst Sliding mode
observer is designed to estimate intake manifold pressure and the model uncertainty arising from the uncertain and time varying
discharge coefficient is compensated by the discontinuity/switching signal of sliding mode observer. This discontinuity is used to
compute coefficient of discharge as a time varying signal. The discharge coefficient is used to tune/correct the intake manifold
model to engine measurements. The resulting model shows a very good agreement with engine measurements in steady as well s
transient state. The stability of the observer is shown by Lyapunov direct method and the validity of the online estimation is
successfully demonstrated by experimental results. OBD-II (On Board Diagnostic revision II) based sensor data acquisition from
the ECU (Electronic Control Unit) of a production model vehicle is used. The devised algorithm is simple enough to be designed
and implemented in a production environment. The online estimation of parameter can also be used for engine fault diagnosis
work.[4]
Research and optimization of intake restrictor for Formula SAE car engine by Pranav Anil Shindhe This research paper aims to
optimize a venturi type restrictor which is to be fitted in the intake manifold of a Formula SAE car engine. The main purpose of
20mm restrictor in intake manifold is to restrict mass flow passing to the engine thus reducing its maximum power. Objectives of
this research is to optimize a venturi type design to allow maximum possible mass flow rate to the engine from 20 mm restrictor
buy reducing the difference in pressure across venturi at all speeds. Analytical calculations are done based on standard results to
get maximum mass flow rate and CFD tool is used to calculate minimum pressure drop across the restrictor buy varying converging
and diverging angles of venturi. It can be observed from CFD results that for converging and diverging angle of 12 degrees and 6
degrees respectively minimum pressure drop can be achieved.
Table 1
CFD results for Different Converging and Diverging Angles of venturi
Iteration No. Converging Angle (Degree) Diverging Angle (Degree) Pressure Difference (Pa)
1
12
6
8560.24
2
14
6
9161.78
3
16
6
9256.88
4
18
6
10009.65

A venturi, generally is used in diverse purpose for various applications in fluid dynamics involving either liquid or gas. In this
project it is brilliantly used in reducing power of engine. As in this competition all the teams are busy trying to squeeze almost all
single horse power available even with the restrictor attached, this gives rise to increasing research in optimization and finding out
alternative technology for increasing mass flow rate to engine. One such technology used is supercharging of air downstream the
venturi to increase the pressure on engine side. A venturi in itself can allow a maximum of 0.0703 kg/s of air flow to engine,
considering no losses in friction and turbulence. From all the research done till now it is clear that at converging angle of 12 degree
and diverging angle of 6 degree we get maximum recovery of pressure. Computational fluid dynamics played important role in all
analysis.[5]

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Review on Design of Intake Manifold For A Formula SAE Car

(IJIRST/ Volume 2 / Issue 12/ 023)

Numerical Simulation of Steady Flow through Engine Intake System Using CFD by Rajesh Holkar et. al The objective of present
study is to predict and analyze the flow through intake manifold and inlet port system using Computational Fluid Dynamics (CFD)
and to validate the prediction by experimental data. Three-dimensional model of air intake system was analyzed by using the
commercially available FLUENT software. The mesh was generated using the tetrahedral hybrid scheme which includes primarily
of tetrahedral mesh elements but may include hexahedral, pyramidal and wedge elements using Hyper Mesh. The pressure
boundary conditions were used to define the fluid pressure at the inlet and outlet of Air Intake System. In the present study, the
CFD code was validated by the experimental work using intake port analysis. The CFD plots give informative pictures of the flow
field, which will help the designer to understand the effect of various components of Air Intake System. The predicted airflow rate
shows good agreement with the experimental results. The results indicate that the CFD model can be used as a tool to understand
the effect of various parts of air intake system for optimization. This in effect will reduce the number of experiments to be carried
out for arriving at final optimized system.CFD contributes to the understanding of three-dimensional flow and also provides
detailed information, where measurements are rather difficult to make. Multi-dimensional modelling of the air intake region
including the inlet manifold, plenum, port and valve is the key for predicting pressure loss influenced by the physical configuration,
The flow is highly three-dimensional. It is strongly dependent on the valve lift except upstream of the port bend, Losses in the
valve clearance are higher. At higher valve lift flow separation is critical. Predicted results inlet port compares favourably with
experiments for velocity magnitude.[6]
Theory of ow distribution in manifolds by Junye Wang Flows in manifolds are of great importance in quite diverse elds of
science and technology, including fuel cells, spargers, solar collectors, microchannels, porous inltration and irrigation. Theory of
ow distribution and pressure drop is vital to predict process performance and efficiency of manifold systems. In this paper, we
examined research and development of theoretical models and methodology of solutions in ow in manifolds and highlight
remarkable advances in the past fty years. The main existing models and solution methods were united further to one theoretical
framework, including Bernoulli theory and momentum theory, and discrete and continuum methodologies. The generalised model
was applicable to not only designs of continuum manifolds but also those of discrete manifolds with constant or varying factors.
The procedure of design calculation is in reality straightforward without requirements of iteration, successive approximation and
computer programme. Finally, in spite of complexity and difculty, the rational yet tractable generalised model of this type can
contribute to the shared goal of cutting the currently cost and performance improvement of new design and development of
distributors, which is central to a chemical engineers toolbox. Measurable progress has been achieved in the development of
mathematical models and the solution methodologies of ow in manifold systems in the past fty years. The generalised theory
makes a step forward in understanding of ow in manifold systems and offers a powerful tool for designs of manifold systems.[7]
Design of intake manifold of IC engines with improved volumetric efficiency by Suresh Aadepu et. al This project intends to
design an Intake Manifold for an 870cc naturally aspirated diesel engine for Greaves Cotton Limited. The current manifold delivers
a maximum volumetric efficiency of 84% at rated torque, i.e. 2400 RPM. The objective of the project is to achieve higher
volumetric efficiency taking the space considerations into account. A methodology for design of intake manifold of IC engines
with improved volumetric efficiency has been presented. This methodology combines optimization using 1-D engine simulation
software and three dimensional, steady state CFD technique, rather than experimental comparison. The 1-D software served as a
platform to obtain the configuration of the manifold which gives better volumetric efficiency, while the CFD simulations enabled
to visualize the ow within the manifold. Such simulations give better insight of ow within the manifolds. Design modifications
could be done using CFD simulations to enhance the overall performance of the system. Using this method, a better design of
manifold giving 7% increase in volumetric efficiency could be achieved. For better results, unsteady state analysis can be carried
out to predict how the intake manifold performs under real conditions. The boundary conditions for these can be obtained form 1D software. The joints can also be made smoother to reduce pressure losses, but the effect of increase in plenum volume has to be
correlated with 1-D software. Also if some changes to the plenum perform in order to guide the ow to the runners by the geometry
of the plenum, the performance of intake manifold will be improved.[8]
Evaluation of CFD Sub-Models for the Intake Manifold Port Flow Analysis by M.M Khan et. al The purpose of this research is to
appraise and simulate computational fluid dynamics (CFD) models, with respect to computing time, which can predict the flow
conditions in an Intake Manifold (IM) of naturally aspirated Spark ignition (SI) engine by using flow analysis numerical model
from ANSYS CFD software (FLUENT 14.0). The simulations are carried out by using different steady state Reynolds Averaged
Navier Stoke (RANS) turbulence models such as Standard k-epsilon (k-) Re-Normalization Group k- (RNG), Realizable k-, komega (k-) and Reynolds Stress Model (RSM). Initial Boundary conditions and validation of simulation results based on
experimental data are used. It is observed that each model produces almost similar results when it comes to pressure drop inside
plenum and inlet velocity. However, RNG k- accounts for swirl dominated flow, predicting better flow conditions inside the
manifold. Therefore, RNG k- is best to capture intake manifold flow turbulent conditions. The investigation of the flow regime,
within the intake manifold, using CFD analysis is possible. However, applying the correct
parameters and CFD models, which can provide economical simulated results, is highly important. This study appraises different
CFD turbulent models and the importance of realistic parameters to successfully predict the flow inside IM. It is noticed that each
model shows variation with the experimental results. While, RNG and RSM shows promising results with lower margin of error
compared to standard k- and k- . For future studies, it is important to analyze each model using transient flow conditions for
better accuracy and predictability of the flow inside IM with part throttle conditions. Furthermore, for future validations high
calibrated sensors should be used to improve the accuracy of experimental data obtained.[9]

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Review on Design of Intake Manifold For A Formula SAE Car

(IJIRST/ Volume 2 / Issue 12/ 023)

A System to Automotive Air Intake System Development by A. S. Patil et. al This Paper reviews the requirements, design
considerations and developments in the field of air intake systems for automotive application. Use of CFD and simulation packages
are elucidated and validated with the help of developmental projects, The importance of Quality tools like Design Review, DVPR
and DFMEA are emphasized with aim to achieve performance and durability requirements. This paper emphasizes the importance
of the systems approach from the concept design phase to the manufacture of the intake system to ensure minimum restriction,
maximum dust holding capacity with long-term durability of total package. The development process, system design specifications,
packaging/clearance checklist and design review checklist are evolved through a regressive process. Design reviews with focus on
air filter and hoses design are the main aspect of the component development process. Quality tools like DFMEA help to reduce
risk factors and increase customer satisfaction by improving design, manufacturing and assembly processes. Although the systems
approach has become an important tool in making intake system more of art than a science, the need for design verification will
always be necessary at the end of the design process. Use of CFD helps to reduce the pressure drop by 18% and temperature by
37% leading to fuel economy advantage of 1%.[10]
II. CONCLUSION
The review paper provides the basic knowledge about the design of intake manifold based on which a new intake manifold can be
designed as per the requirement of the engine. The flow analysis using Computational fluid dynamics (CFD) helps to analyze the
flow in the intake manifold.
REFERENCES
[1]

Ceviz, M. a. & Akin, M., 2010. Design of a new SI engine intake manifold with variable length plenum. Energy Conversion and Management, 51(11),
pp.22392244.Available at:http://linkinghub.elsevier.com/retrieve/pii/S0196890410001329.
[2] Potul, S., Nachnolkar, R. & Bhave, S., 2014. Analysis Of Change In Intake Manifold Length And Development Of Variable Intake System. , 3(5), pp.223
228.
[3] Kennedy, Woods, F., 2011. Development Of A New Air Intake And Exhaust System For A Single Seat Race Car. , p.8.
[4] Butt, Q.R. et al., 2013. Modeling and online parameter estimation of intake manifold in gasoline engines using sliding mode observer. Simulation Modelling
Practice and Theory, 32, pp.138154. Available at: http://dx.doi.org/10.1016/j.simpat.2012.12.001.
[5] Shinde, P.A., 2014. Formula SAE car engine. , 4(4), pp.48.
[6] Rajesh Holkar, 2015. Numerical Simulation of Steady flow through engine intake system using CFD\n. IOSR Journal of Mechanical and Civil Engineering
(IOSR-JMCE), 12(1), pp.3045. Available at: http://www.iosrjournals.org/iosr-jmce/papers/vol12-issue1/Version-2/E012123045.pdf.
[7] Wang, J., 2011. Theory of flow distribution in manifolds. Chemical Engineering Journal, 168(3), pp.13311345. Available at:
http://linkinghub.elsevier.com/retrieve/pii/S1385894711002300.
[8] Suresh.Aadepu; I.S.N.V.R.Prasanth; Jarapala. Murali Naik, 2014. Design of intake maniold of IC engine with improved volumetric efficiency. Engineering
& Technology, 1(6). Available at: http://www.ijmetmr.com/oljune2014/Article6.pdf.
[9] Khan, M.M. & Salim, S.M., 2013. Evaluation of CFD Sub-Models for the Intake Manifold Port Flow Analysis. , pp.9394.
[10] Patil, a S., Halbe, V.G. & Vora, K.C., 2005. A System Approach to Automotive Air Intake System Development. Available at: http://dx.doi.org/10.4271/200526-011.

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