th

V International Symposium on “Fusion of Science & Technology”,

New Delhi, India, January 18-22, 2016

ID: 2016-ISFT-346

Analysis of Air Intake for Formula SAE Vehicle

Shubham Raj1, Ashish Kr. Singh2, Tuhin Srivastava3, Vipul Vibhanshu4
1,2,3,4
Undergraduate Scholar, Department of Mechanical Engineering,
Krishna Institute of Engineering and Technology, Ghaziabad, UPTU
1
[email protected]

Abstract: This paper aims to the design and manufacture of • Conform to FSAE regulations: The main restrictions on
an intake system for a 600cc Formula SAE engine by the air intake manifold are that it has to have a 20mm
optimizing a venturi type restrictor which is to be fitted in restrictor and no throttling downstream of the restrictor.
the intake manifold of a Formula SAE car engine. The
engine analyzed for intake manifold was Honda CBR 600rr. • Fits into the current chassis of the car:The air intake
The main purpose of 20mm restrictor in intake manifold is manifold must fit into the current chassis without
to restrict mass flow passing to the engine thus reducing its obstructing other main components of the car.
maximum power. Objectives of this paper is to optimize a 2. INTAKE MANIFOLD
venturi type design to allow maximum possible mass flow
rate to the engine from 20 mm restrictor buy reducing the The purpose of intake manifold is allowing mass flow of air
difference in pressure across venturi at all speeds. passing to the engine thus improving the performance of
Analytical calculations are done based on standard results engine with consideration of all the FSAE rules and
to get maximum mass flow rate and CFD tool is used to regulations. This intake manifold is thereby connected with
calculate minimum pressure drop across the restrictor buy the cylinder head of engine which is guided by the air flow
varying converging and diverging angles of venturi. It can passing through 20mm restrictor.
be observed from CFD results that for converging and
diverging angle of 14 degrees and 6 degrees respectively
minimum pressure drop can be achieved.

Keywords: Formula SAE, Intake Restrictor, Flow

optimization, CFD.

1. INTRODUCTION
Formula SAE is a student competition organized by Society
of Automotive Engineers (SAE), where in students are
supposed to design, manufacture and run a prototype of
open wheel racing car. This competition is conducted in
various parts of world every. Formula SAE rules committee
has imposed a rule of adding a 20 mm restrictor to intake
manifold and also states that all air flowing to the engine
should pass through this single restrictor bet it a single Fig. 1. Intake Manifold with its part
cylinder or multi cylinder engine. This rule limits the The fluid element enters into the air induction system by
maximum power of engine by reducing mass flow rate first passing through the air filter. This is to ensure that the
flowing to engine. Thus a restrictor should be efficiently air is free from particulates that could potentially harm the
designed and validated to allow maximum possible air flow internal components of the engine. The fluid element then
and maintain minimum pressure difference across the enters the throttle body, which is a throttling device
restrictor. responsible for regulating the mass flow rate of air into the
Engines used in this competition are majorly 600cc engines engine using a butterfly valve. Once passing through the
which revs up to 14000 rpm and gives 110 hp of output throttle body, the fluid element enters into a
[1].It is beneficial to design an intake manifold that best converging/diverging nozzle, with the throat diameter that
utilizes the available airflow for increased of the 20.0 mm restrictor regulated by the Formula SAE
performance.Based on FSAE competition rules, the rules. The fluid element increases and decreases its velocity
following major design specifications were developed: in the converging and diverging sections.

ISBN: 978-93-84935-64-1 ♦ 457 ♦

 Analysis of Air Intake for Formula SAE Vehicle

The diffuser represents the trumpet-styled

styled inlet tube that
connects the throttle body and the plenum. It is comprised of
a flange attachment to the throttle body ody with the inlet
diameter matching that of the inner diameter of the throttle
body. The inlet then converges to the restrictor diameter.
After the restrictor, the airway then diverges until meeting
the inner diameter required for attachment to the plenum.
A plenum is a relatively large chamber between restrictor
and primary runners. The plenum is designed to deliver
equal flow to all cylinders and to damp out pulsation caused
by intake stroke of the engine. The plenum also allows the
gases to slow down and gain density. If the plenum volume
is too high then throttle response is very poor and if plenum
volume is very low then it will create negative pressure
inside plenum which will affect efficiency of engine.
Fig. 2. Orifice and Venturi
The main function of the intake system is to direct air from
surrounding to the combustion chamber of the engine. The 3.2 CONSTANTS AND VARIABLRS IN DESIGN OF
design of the intake system will have a significant effect on VENTURI
how the engine runs. The key of making power is to fill the
combustion chamber with maximum amount of air and fuel We have two dimensions on which the venturi will perform
mixture. and these are converging diverging angles and length of
venturi. We also know that temperature at inlet is ambient
The general rule is that you should begin with a runner and pressure at inlet is atmospheric. For boundary
length of 17.8 cm for a 10,000 rpmpeak torque location, conditions at outlet of venturi we can have pressure,
from the intake opening to the plenum chamber. velocity or mass flow rate. According to the laws governing
fluid dynamics, a fluid’s velocity must increase as it passes
3. DESIGN EXPLORATION through a constriction to satisfy the principle of continuity,
Design consistedofappropriately calculated steps which at while its pressure must decrease to satisfy the principle of
every instance provide proper connectivity between the last conservation of mechanical energy. Thus a drop in pressure
and next step involved in research of venturi. negates any gain in kinetic energy a fluid may accrue due to
its increased velocity through a constriction. An equation for
3.1 SHAPE OF RESTRICTOR the drop in pressure due to the Venturi effect may be
derived from a combination of Bernoulli’s principle and the
The shape of a restrictor can be as simple as a plate with the continuity equation. The parameters are important for
mandated dimensions machined into it, and placed calculating actual flow conditions inside and outside the
anywhere along the air intake system. But a simple orifice restrictor [2]. These parameters also provides rigid base for
plate would create a lot of pressure loss downstream of the boundary conditions to be used in CFD analysis.
restrictor, and the resultant effect would decrease the
efficiency of the line of airflow. There were some other Calculations:
factors also which forced us to switch from simple orifice The values taken for substitution in Equation are:
plate to Convergent-Divergent Nozzle this includes the co-
efficient of discharge which is higher for the Convergent- Pt = 101325 Pa
Divergent Nozzle. Therefore it was decided to design T = 300K
Convergent-Divergent Nozzle that replaced the orifice plate γ = 1.4
as an air intake restrictor.
R (air) =0.286 kJ/Kg-K
This device will have throat diameter of 20 mm as per rules A = 0.001256 m2
of the competition.With the basic information for throttle
body diameter for an engine with 600 cc of displacement M = 1 (Choking Conditions)
and for revolutions per minute of 14000, the diameter of Result:: Mass Flow Rate at Choking = 0.0703 kg/s
throttle body is taken to be 40mm; the same is widely used
in competition. This dimension will be the diameter of 3.3 DATA ANALYSIS
venturi at inlet and outlet.
A. Aim to maximize pressure recovery at outlet
B. Variables

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V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18
18-22,
22, 2016 ♦ 458 ♦
 Analysis of Air Intake for Formula SAE Vehicle

a. Dependent Variables: Delta Pressure (= Inlet Pressure – 3.4 UNDERSTANDING

ING COMPRESSIBLE FLUID
Outlet Pressure) DYNAMICS
b. Independent Variables: Converging angle and Diverging The most important parameter in compressible flows is
angle Mach number Ma=V/C =V/C where V is flow velocity and C is
c. Constants: Inlet, Outlet and Throat diameter, Type of speed of sound. If Mach number is less than 0.3,
Fluid -Air, Temperature - 300K compressibility effects can be neglected as there is around 3
C. Boundary Conditions % change in density. Whereas if Mach number is from 0.3
a. Inlet Face: Total Pressure = 1 bar to 1 flow is called subsonic and if Ma>1 flow is supersonic,
s
b. Outlet Face: Mass Flow Rate = 0.0703kg/s [4] in this regions compressibility increases and its effects are
considerable. And also a great discharge is observed in this
region [5-6].

Fig.3. Formulae for Mass Flow Choking [3]

Fig. 4. Variation of Cd with Mach number Fig. 5. Density change vs. Mach number

Applying the knowledge above to a converging

converging-diverging to engine will be passed through this single venturi, pressure
nozzle we can easily analyze that density of air is reduced available at inlet to engine will be very less. Thus engine
drastically when passing through the restriction. It means work is increased to high levels and it is forced to pull more
that pressure on downstream side is reduced. As all the air air from venturi so that there is enough air available inside

th
V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18
18-22,
22, 2016 ♦ 459 ♦
 Analysis of Air IIntake for Formula SAE Vehicle

combustion chamber to burn fuel completely. This situation converging cone. Diverging cone angle was set to 6 degree
occurs usually at high rpm around 6000 and more. This is as it was found that any increase or decrease in angle caused
not good for engine as it cannot squeeze out maximum streamline disturbance and drop in pressure at downstream
power that is available and the car moves slowly. Thus our side. It was finally observed from various simulations that
aim is to reduce this pull from engine and recover maximum pressure recovery was maximum when converging angle is
amount of pressure at outlet of venturi [7-8].
8]. 14 degree and diverging is 6 degree.
4. STUDIES AND FINDINGS Following are the images which show other operational
parameters for final design of venturi.
Once we have found out all data that we have for solving
our problem, we now move towards studying the problem 5. CONCLUSIONS
and finding out dimensions of venturi which will provide us
minimum pressure drop across the venturi. So to do the The optimum solution to achieve maximum possible mass
study we have started with assuming some dimensions of flow rate of air as quickly as possible is to minimize the
diverging and converging angles by basic knowledge of pressure loss through the flow restriction device. The best
functioning of venturi. CAD modelling was done using way to achieve it is by passing it through a venturi design.
Autodesk Inventor 2014 and then analysed in Flow In this project venturi is brilliantly used in reducing power
Simulation for following boundary conditions: of engine. As in this competition teams are busy trying to
squeeze almost all single horse power available even with
Inlet: Total Pressure = 101325 Pa the restrictor attached, this gives rise to increasing research
in optimization and finding out alternative technology for
Outlet: Mass flow rate = 0.0703 kg/s increasing mass flow rate to engine. From the collected data
Iterations have been carried out with set of converging and and gathered information from various simulations one has
diverging angles. These iterations were used for the flow reached to this conclusion that the Venturi with 140 and 60
simulation of venturi also at different angles. ANSYS 13.0 as its converging and diverging angle respectively will
was used for CFD analysis of the venturi. perform the optimized flow.

These iterations have been tabulated as follows

follows- ACKNOWLEDGEMENT

TABLE 1. I would like to express my sincere thanks to all my friends

who helped me to bring up this paper from nowhere to its
Pressure publication. I would like to extend my gratitude to Ashish
Converging Diverging Kr. Singh, Tuhin Srivastava and Vipul Vibhanshu of
S.No(Iterations) difference
Angle Angle Mechanical department, KIET who contributed their time
(Pa)
and helped me in writing this paper and completing in
1. 160 60 9256.68
timely manner. I would also thank them for making this
2. 140 60 9161.78 paper a successful one.
3. 180 80 10009.65
REFERENCES
[1] Shinde P.; Navale K.Research and optimization of
intake restrictor for Formula SAE car engine, 2014,
4, 4.
[2] Venturi description – Flow through a venturi
available at: en.wikipedia.org/wiki/Venturi_effect
[3] www.grc.nasa.gov/WWW/k-12/airplane/mflchk.html
[4] Singhal A.; Parveen M.; Air flow optimization via a
venturi type air restrictor, London UK, WCE, 2013.
[5] Section 8, Sonic Flow Nozzles and Venturi —
Critical Flow, Choked Flow Condition,
ASMEPublication.
[6] Modi P. N.; Seth S. M. Hydraulics and Fluid
Mechanics, Rajsons Publication Pvt. Ltd, New Delhi.
[7] FSAE Variable Air Intake Consulted on – 22 JAN
Fig. 6. CFD analysis of venturi with 140 and 60 as its converging 2013
and diverging angle respectively [8] http://poisson.me.dal.ca/~dp_06_9/concept.htm
After understanding all the above master iterations, much [9] http://www.engineeringtoolbox.com/orifice-nozzle-
http://www.engineeringtoolbox.com/orifice
iteration was performed to see for other valves of venturi-d_590.html.

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V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18
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