Design of Throttle Body A Comparative Study of Different Shaft Profiles Using CFD Analysis

Int. J. Chem. Sci.
: 14(S2), 2016, 681-686

ISSN 0972-768X
www.sadgurupublications.com
DESIGN OF THROTTLE BODY: A COMPARATIVE STUDY

OF DIFFERENT SHAFT PROFILES USING CFD ANALYSIS
M. BALAJI*, K. AMAL SATHEESH, G. SANJAY and
HAYNES K. JOB
Department of Mechanical Engineering, SRM University, CHENNAI (T.N.) INDIA
ABSTRACT
Throttle body assembly plays a vital role in metering the air flow to the engine. It mainly consists
of a butterfly valve to vary the flow area to control air flow rate through it. There is hardly any established
procedure to design a throttle body assembly based on engine specification. In this project we intend to
design and analyze the throttle body assembly using Computational Fluid Dynamics and compare two
throttle body shaft profiles. To start with throttle bore diameter is calculated based on engine air flow
requirements. The throttle body shaft configurations are modelled and using CFD analysis we arrive at the
best configuration which will provide optimum airflow. The airflow rate for different throttle opening is
predicted through detailed analysis. Finally, we intend to validate the results obtained from the flow
analysis by fabricating the throttle body assemblies and testing them.
Key words: Throttle body shaft, Bore diameter, CFD Analysis, Airflow rate.
INTRODUCTION
A throttle body is the part of the air intake system in fuel injected automobiles that
controls the amount of air flowing into the engine, in response to driver accelerator pedal
input. The throttle body is usually located between the air filter box and the intake manifold,
and it is usually attached to, or near, the mass airflow sensor. When the driver presses on the
accelerator pedal, the throttle plate rotates within the throttle body, opening the throttle
passage to allow more air into the intake manifold.
The largest piece inside the throttle body is the throttle plate, which is a butterfly
valve that regulates the airflow. A butterfly valve is a valve which can be used for isolating
or regulating flow. The closing mechanism takes the form of a disk. Operation is similar to
________________________________________
*
Author for correspondence; E-mail: [email protected]
682 M. Balaji et al.: Design of Throttle Body….
that of a ball valve, which allows for quick shut off. Butterfly valves are generally favoured
because they are lower in cost to other valve designs as well as being lighter in weight,
meaning less support is required. The disc is positioned in the centre of the pipe; passing
through the disc is a rod connected to an actuator on the outside of the valve. The disc is
always present within the flow, so a pressure drop is always induced in the flow, regardless
of valve position.
A butterfly valve is from a family of valves called quarter-turn valves. In operation,

the valve is fully open or closed when the disc is rotated a quarter turn. The "butterfly" is a
metal disc mounted on a rod. When the valve is closed, the disc is turned so that it
completely blocks off the passageway. When the valve is fully open, the disc is rotated a
quarter turn so that it allows an almost unrestricted passage of the fluid
Using CFD the flow characteristics of the air flow inside the throttle body can be
assessed. Thus the project aims at bringing out the better profile by analyzing the simulation
data and validating it through experimentation
Literature survey
In the paper ‘DESIGN and Optimisation of Throttle Body Using CFD Analysis’ by
Suresh Kumar et al.1 have carried out flow simulation of flow through throttle body and have
optimized the throttle shaft configuration, studied effects of throttle opening on flow field
and airflow rate, effects of bypass screw position on air flow field, engine performance and
emissions and also effects of throttle bore diameter on airflow and engine power developed.
This paper is the base paper for this project work which helped setting the goal for this
project.
In the paper ‘Modelling The Time-Dependent Flow Through A Throttle Valve’ by

Alsemgeest et al.2 have carried out simulation of time-dependent flow through throttle valve
to determine flow mechanisms for various throttle plate angles and compared results with
hexahedral and tetrahedral meshes.
‘Internal Combustion Engine Fundamentals’ by John B Heywood3 is a book that

presents fundamentals and factual developments of the science and engineering underlying
the design of combustion engines and turbines. This book helped us in understanding the
basics of engine and using the parameters such as mean piston speed the throttle body was
designed.
Int. J. Chem. Sci.: 14(S2), 2016 683
‘Back to Basics’ by Prof. Gordon Blake4 which discusses the fundamentals and
empiricism in engine design. This technical magazine helped us in understanding the
relationship between mean piston speed and mean gas velocity which is an essential
parameter in determining the throttle bore diameter.
Methodology
The methodology followed for completing this project is:
• Literature survey: Various research papers, journals and textbooks are to be

referred to acquire knowledge in the subject.
• Determination of throttle body bore: A benchmark engine has to be selected and
the throttle body has to be designed to meet its specifications.
• Modeling of various shaft profiles: The shaft profiles as well as their assemblies
should be modeled in modeling software.
• Flow simulation: The flow through the model has to be simulated and analyzed
using CFD solvers.
• Experimental validation: An experimental setup has to be fabricated and the
simulation data has to be experimentally validated.
Design and specification
The design procedure aims at designing the throttle body with optimum dimensions.
Initially a benchmark engine had to be chosen. The engine we chose was the Maruti Suzuki
Swift Petrol engine
Benchmark engine specifications
Table 1: Engine specifications
Engine capacity (Vd) 1197 cc

Max power 85 hp@6500 rpm (N)
Bore (B) 73 mm
Stroke (L) 71.5 mm
Cont…
Engine capacity (Vd) 1197 cc

Inlet port diameter (Di) 34 mm
Torque (T) 115 Nm
Visualisation of back flows downstream of the throttle valve
Fig. 1: Vector plot of circular profile
Fig. 2: Vector plot of rectangular profile

Observations
Once the assembly was done, to carry out the experiment the air blower was attached
to the inlet pipe. When the blower is switched on the manometer shows height difference
due to the pressure drop across the valve. The readings were taken at 30, 45, 60 & 90 (wide
open) opening of the valve. The pressure drop is calculated using manometer formula & was
taken for across the valve and for across the system as well. This was done for both the
circular and rectangular profiles throttle bodies.
Int. J. Chem. Sci.: 14(S2), 2016 685
Table 2: Pressure drop across the butterfly valve
300 450 600 900

Angle H P H P H P H P
(mm) (Pa) (mm) (Pa) (mm) (Pa) (mm) (Pa)
Circular 152 1489.6 72 705.6 24 235.2 9 88.2
Rectangular 121 1185 67 656.6 22 205.8 9 88.2
ΔP 304.6 49 29.4 0
Table 3: Pressure drop across assembly
Angle 300 450 600 900

H P H P H P H P
(mm) (Pa) (mm) (Pa) (mm) (Pa) (mm) (Pa)
Circular 149 1460.2 103 1009.4 55 539 13 127.4
Rectangular 115 1127 70 686 51 499.8 70 68.6
ΔP 333.2 323.4 39.2 58.8
RESULTS AND DISCUSSION
The major focus on the simulation were on the sudden pressure drop created across
the butterfly valve at various valve opening angles and the presence of backflows which
adversely affect the flow through the throttle body. The results from the simulation were
compared with data obtained from the experiment. The conclusion drawn is as follows:
• The flow simulation showed the pressure drop across rectangular shaft profile to
be less than that across the circular profile, which is similar to the result
obtained from the experiment.
• The highest difference in pressure drop across the butterfly valve was expected
30o valve opening which was in agreement with the experimental result.
• The difference in pressure drop for both shaft profiles decreased suddenly after
30o of valve opening as predicted.
• The pressure drop difference at 45o, 60o and 90o of valve opening were not as
significant as that seen at 30o valve opening.
Fig. 3: Comparison chart for theoretical and experimental pressure drop
CONCLUSION
The throttle bore parameters were calculated using flow equations and was modeled.
The flow through the throttle bodies each with different shaft profiles were simulated and
compared experimentally. Data obtained from both showed the rectangular shaft profile to
have less pressure drop as compared to the circular one. The throttle body with rectangular
shaft profile showed better flow characteristics with minimal backflow and reduced
turbulence downstream of the butterfly valve thus proving to be the better choice. An
internal combustion engine equipped with such a throttle body will have better breathing
capacity which would mean an improvement its Performance, fuel economy and emissions.
REFERENCES
1. R. Alsemgeest, C. T. Shaw and Richardson, Modelling the Time-Dependent Flow

Through a Throttle Valve- SAE Paper 2000-01-0659 (2000).
2. J. Suresh Kumar, V. Ganesan, J. M. Mallikarjina and S. Govindarajan, Design and
Optimization of a Throttle Body Assembly by CFD Analysis, Indian J. Engg. Mater.
Sci., 20, 350-360 (2013).
3. J. B. Heywood, Internal Combustion Engine Fundamentals (McGraw Hill) (1988).
4. Prof Gordon Blake, Back to Basics, Insight: Engine Tech. (2000).
Accepted : 01.07.2016

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Int. J. Chem. Sci.

: 14(S2), 2016, 681-686

DESIGN OF THROTTLE BODY: A COMPARATIVE STUDY

Department of Mechanical Engineering, SRM University, CHENNAI (T.N.) INDIA

A butterfly valve is from a family of valves called quarter-turn valves. In operation,

In the paper ‘Modelling The Time-Dependent Flow Through A Throttle Valve’ by

‘Internal Combustion Engine Fundamentals’ by John B Heywood3 is a book that

The methodology followed for completing this project is:

• Literature survey: Various research papers, journals and textbooks are to be

Design and specification

Table 1: Engine specifications

Engine capacity (Vd) 1197 cc

Engine capacity (Vd) 1197 cc

Visualisation of back flows downstream of the throttle valve

Fig. 1: Vector plot of circular profile

Fig. 2: Vector plot of rectangular profile

Table 2: Pressure drop across the butterfly valve

300 450 600 900

Table 3: Pressure drop across assembly

Angle 300 450 600 900

RESULTS AND DISCUSSION

Fig. 3: Comparison chart for theoretical and experimental pressure drop

1. R. Alsemgeest, C. T. Shaw and Richardson, Modelling the Time-Dependent Flow

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