Design, optimisation and testing of a 200cc single cylinder petrol engine for FHSAE car for mid-range torque improvement

Abstract

The present work aims to optimize the intake manifold design suitable of a 200cc KTM engine, n order to get the best power and torque output from the engine in the mid RPM range. Currently this engine produce majority of its power output at very high RPM, design will be such that it performs best at mid-range, this will increase the drivability of the vehicle as the engine will not need to be revved hard to accelerate, thus increasing fuel efficiency of the vehicle. After necessary calculations has been carried out for the size and shape of the manifold, the same has been modeled using Solidworks and subsequently flow analysis was carried out using ANSYS. With a preliminary design is finalized, after several steps of iteration, a prototype was created using Rapid Prototyping Technique (RPT), for experimental validation with the engine. Its performance was evaluated to make further changes in the final design and thereon the final product has been manufactured using 3D printing technology. Performance characteristics assessment with the optimized design was performed to assess the torque and volumetric efficiency. With the optimized design, an increase in volumetric efficiency by 6.1 % at the desired RPM range and an increase of torque by 1.1 Nm respectively, has been achieved.