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Supercharger Design
Supercharger Design
ENGINE PERFORMANCE
INTRODUCTION
The development of a supercharger is an important endeavor in the fields of automotive and
mechanical engineering, with the goal of improving the performance and efficiency of internal
combustion engines. This novel device works on the fundamental principle of forced induction,
which involves compressing incoming air to provide more oxygen to engines, resulting in
increased power output. To achieve optimal compression ratios, a well-executed supercharger
design requires a delicate balance of factors such as rotor and housing geometry, material
selection, and precision engineering. It is critical in increasing engine power, improving throttle
response, and overall vehicle performance. To ensure seamless integration, engineers must
consider factors such as reliability, heat management, and compatibility with the engine
system.As the automotive industry prioritizes fuel efficiency and performance, the design of
superchargers remains a dynamic and critical aspect of field innovation.
PROBLEM STATEMENT
Design a supercharger for 450hp power and 6650 rpm for a vehicle Ford Raptor R and desired
output:- 700 hp. Many vehicles face limitations in engine performance, affecting speed and
efficiency. Traditional engines lack power, especially at lower speeds or during acceleration.
This hampers overall vehicle performance and user experience.
OBJECTIVES
➢ Boost Power: Create a supercharger system that increases engine power, improving
vehicle acceleration and speed capabilities for better performance.
➢ Enhance Efficiency: Design the supercharger to optimize fuel usage, making the vehicle
more fuel-efficient without compromising on power.
➢ Ensure Simplicity: Develop a user-friendly supercharger design that's easy to understand,
assemble, and operate, suitable for study purposes.
➢ Cost-Effectiveness: Build the supercharger system using affordable materials and
methods, ensuring it remains budget-friendly for educational purposes.
➢ Learning Experience: Provide a practical learning opportunity for students to understand
the principles of supercharger design, mechanics, and their impact on engine
performance.
Drive Mechanism:
drive power =boost* desired airflow/229
drive power =60.917 hp
dividing drive power by 97 percent for belt efficiency and 60 percent adiabatic efficiency.
knowing this number we are looking for a belt which is able to carry 103 hp power.
pulley ratio= supercharger rpm at desired flow rate/ gear ratio* engine redline rpm
pulley ratio= 1.5
=60*550 lb-ft/sec
force = power/velocity
force = 60 pounds= 220N
new fuel pressure= stock fuel pressure*(old airflow rate/new airflow rate *pressure ratio)2 +
boost
new fuel pressure= 104 psi
V_tip = 𝝅D_i * N / 60
impeller diameter = sqrt(4 * Q / (𝝅 * V_tip * n))
(impeller blade angle) beta = tan^-1((V_tip * U) / (C_m * W_1))
Impeller diameter = 0.12 mm
MATERIAL SELECTION
1) Rotar: A supercharger's rotor is typically made of high-strength materials to withstand the
high-speed rotation as well as the forces involved in compressing and delivering air to the
engine. The materials used are
I. Aluminum: It is a lightweight and durable material commonly used for
supercharger rotors. A356 and A380 are commonly used aluminum alloys
II. Titanium: Ti-6Al-4V is commonly used Titanium alloy
III. Magnesium: AZ91D and AZ61D are mostly used Magnesium alloys.
2) Casing: The casing or housing of a supercharger, also known as the supercharger housing or
supercharger case, is an essential component that encloses the internal components of the
supercharger and provides structural support, airflow management, and connections to the engine
and intake system. The casing is typically made from durable materials that can withstand the
high-pressure and high-temperature conditions within the supercharger .Some examples of
specific materials used in the casings of popular superchargers:
FUTURE SCOPE
● Improved Efficiency: Advancements in materials and design will lead to more efficient
superchargers.
● Hybrid and Electric Vehicles: Superchargers can enhance the performance of hybrid
setups and potentially boost power in electric vehicles.
● Emissions Reduction: Superchargers can enable downsizing, reducing emissions without
sacrificing performance.
● Tuning and Customization: Superchargers offer tunability for enthusiasts and will
continue to grow in the aftermarket segment.
● OEM Integration: Automakers may integrate superchargers to meet emission standards
and improve performance.
CHALLENGES
➢ Emissions and Fuel Efficiency: Balancing performance and fuel efficiency is a challenge
as emission standards become stricter.
➢ Electrification: Superchargers may become less relevant with the shift to electric
vehicles.
➢ Heat Management: Effective cooling solutions are needed to manage heat generated by
superchargers.
➢ Cost: Reducing the cost of designing, manufacturing, and installing supercharger systems
is an ongoing challenge.
➢ Reliability: Ensuring long-term reliability is crucial due to the wear and tear from high
rotational speeds.
CONCLUSION
Supercharger design remains a dynamic and critical aspect of automotive innovation, aiming to
strike the delicate balance between performance and efficiency. The pursuit of increased power
and improved environmental sustainability aligns with the industry's focus on technological
advancements. As engineering and material science continue to advance, superchargers will play
a pivotal role in shaping the future of automotive performance and efficiency.