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ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION

VARIABLE/ CONVENTIONAL INTAKE &

EXHAUST
Prepared by: Presented to :
Amr Mohamed Rabea Dr/ Mohamed Abdelaziz
Amr Sayed Mohamed
Ibrahim Mostafa Saleh
Omar Nasser Khalaf
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INTRODUCTION
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Introduction
The intake and exhaust system are two of the most important components related to the engine. The design of the
intake and exhaust system plays a very important role for the engine efficiency and its overall performance.

Intake System Main Components Exhaust System Main Components

Air Source Location Exhaust Manifold

Air Filter Catalytic Converter

Plenum Mufflers

Restrictor

Variable/Conventional Intake
Runners
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Scope
Intake System Exhaust System

Our main goal is to design a an intake system which We aim to design a system which will help the
can enhance the engine overall efficiency. engine to operate at best condition with taking care
of the environmental rules and the regulations.
Manifold design for proper distribution of air
mixture between cylinders. Exhaust Manifold design for decreasing the
friction losses
Variable intake design and tuning to increase
volumetric efficiency. Decreasing the noise occurred in exhaust
manifold.
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Project Overview

Hand Calculations Modeling Process CAD Design

Final Project Report CFD Analysis

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INTAKE SYSTEM
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Filter
Function

Impurities

Laminar Flow

Obstruction to air flow rate

Effect of air filter on flow rate
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Throttle:

Types:

Barrel Throttle

Advantages

Disadvantages
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Throttle:

Sliding Throttle

Advantages

Disadvantages
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Throttle:

Butterfly Throttle

Improvements
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Air Intake Restrictor

What is it ?

How does it affect engine

performance?

FSAE Regulations

Why these limitations are imposed?

 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Plenum

Function

Even distribution

Reservoir

Design Parameters

Shape

Volume

Space Constraints

Pressure Responce
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Runner:

Design

Function
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Runner:
Acoustic wave
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Runner Tuning

Varying lengths and diameters for a certain RPM range

Low rpm : Longer and narrower runner

High rpm : Shorter and wider runner

Runner length Limitation ex: 30~45cm

So we get know when we are able to provide the ramming effect at what Harmonic Order

Power loss in other RPM ranges

Due to the lower pressured air column

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EXHAUST SYSTEM
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Manifold

Function

Scavenging

Design parameters

Length

Radius

One-direction flow

Design Considerations
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Design
Considerations
Energy wave and back pressure

Tunning

Solve by increasing the diameter

 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Design
Considerations
Scavenging

Negative Pressure

Firing order

Controlled by the diameter

 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Design
Considerations
Radius Optimization

Decrease back pressure and increase

scavenging

Surface Envelope

Body frame restrictions

 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Exhaust System:

Collecter:
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Exhaust System:

Catalytic
Converter
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Exhaust System:

Muffler:
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SIMULATION
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

CFD Simulation
Process
After conducting a rough revised hand
calculations and basic concept CAD
drawings for our systems. The second
important process is to use advanced
simulations techniques using ANSYS or
OpenFoam software to obtain optimum
length/volume of the runner.
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Our CFD simulation technique will be based on the Two-Step Simulation

process which starts by performing full steady CFD analysis in order to
obtain:
1. Constant boundary conditions like Mass Flow Rate, Total Pressure or Static Pressure are applied.

2. Analyze Individual runners 1 by 1.

3. Check for the velocity vectors and flow.

4. Take Chop Plots at various sections to check for eddies, pressure drop, recirculation or vortex
formation.

5.Ensure good velocities and pressure drop variations from runner to runner within 3-4%.

When we finish all the previous step we will go through a verification

process to ensure that we solved the right model and to know how accurate
our design is.
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Secondly, we start to the second step to have a deeper look into

the flow analysis. By exporting our simulation to the transient
state process this includes:
1. Using the same mesh that was used for the steady state process (may be fined if needed) to continue
our simulation

2. Developing the proper boundary conditions, using the 1-D gas wave code or ANSYS user defined
functions.

3.Analyze the backflow into the runners.

4. Analyze the flow velocity vectors at various section in the plenum.

5. Check for how the Intake Manifold distributes the air to each cylinder in a transient run condition.

Then an reverse-turn design process takes place where we add modifications

on our CAD model in order to enhance performance.
 ASU RACING TEAM R&D GRADUATION PROJECT PRESENTATION : VARIABLE/ CONVENTIONAL INTAKE & EXHAUST PRESENTED TO : DR/ MOHAMED ABDELAZIZ

Last part would be conducting a research work on the

fluid-solid interaction (FSI)
Fluid structure interaction is one of most complex engineering
analyses, coupling CFD and finite element structural and/or
thermal analysis. In an FSI calculation, the solid surfaces act as
interfaces between the fluid and solid domains to provide
transfer of loads- mechanical or thermal. The CFD solution
provides unsteady flow-field solutions for pressure or heat
fluxes on solid surfaces, then the FEA solver calculates solid
deformations or temperatures based on the CFD results. The
deformed solid surfaces will in turn constitute a new boundary
for CFD calculation, which leads to a different pressure or
thermal loading. Thus, the FSI analysis requires a two-way
interaction and a fully coupled iterative solution at each time
level.
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THANK YOU