Air Flow Optimization through an Intake System for a Single Cylinder Formula Student(FSAE) Race Car

Abstract

This paper focuses on design and manufacture of an intake system for FSAE single cylinder race car engine. The rules impose the introduction of a restrictor in the intake system of the engine. The use of restrictor chokes the engine which reduces its performance and power output and hence necessitate its selection and improvisation. The objective of this paper is to optimize the Venturi to maintain a constant mass flow rate and to maximize the delta pressure after passing through the restrictor. The volume of the Plenum and the size of the Runner were determined for efficient working of the intake system. Analysis was done in iterations by changing the converging and diverging angles of the Venturi. Experimentation showed that converging and diverging angles of 12&6 prove to maximize the pressure lost due to the 20mm restrictor. Plenum and Runner were implemented to recover the pressure lost after the restriction through its way to the engine. The overall design is modelled on a 3D modelling software and the analysis is performed on a flow simulation software. Rapid prototyping being the core manufacturing process, fused deposition modelling was done followed by the process of Fiberglass reinforced lining. This overall process was considered due to the final product being lightweight , profile desired design, elimination of finishing processes and increased strength of the product.