Optimization Design Parameters of Intake Manifold for Natural Aspirated Engine

Abstract

Improving engine performance, reducing fuel consumption costs and decreasing emissions are the primary objectives of vehicle manufacturers. Aware on the fluctuation of the national gas price, an idea had been proposed on improving the air intake system in order to get a good fuel economy and a better engine performance. The purpose of this study is to design new intake manifold on air intake system for the natural aspirated car with the selected parameters of runner length (A), runner diameter (B), plenum Volume (C), and surface roughness (D). Necessary steps have been taken involving the Design of Experiment (DOE) to find the optimum result for all the factors that have been selected by using Box-Behnken design (BBD). The data of torque and fuel consumption are obtained from the 1D Computational Fluid Dynamics (CFD) usingthe AVL Boost software. Within the range studied, the optimized parameters value for the maximum engine performance and minimum fuel consumption was at the A = 200.00mm, B = 33.56mm, C = 0.5L and D = 0.15µm. The maximum engine performance and minimum fuel consumption were determined as 99.541Nm/rpm and 8.8652×10^-4 kg/s, respectively. Then, the new model of the intake manifold with optimum parameters was developed using NX8.0. Apart from that, polyamide and injection molding had been identified as the best material and manufacturing process for the development of the intake manifold.