FORMULA UOTTAWA IC

Intake Manifold Design

Designing, simulating and validating an intake manifold for a Suzuki GSX-R600 engine to improve volumetric efficiency, airflow distribution and overall engine performance.

OBJECTIVE

Optimizing Engine Airflow

The objective of this project was to design and optimize an intake manifold for a Suzuki GSX-R600 engine targeting improved volumetric efficiency, airflow distribution and overall engine performance.

With the FSAE rulebook mandating an intake restrictor of 20mm and the vehicle imposing strict packaging constraints, the intake manifold had to be designed within the tire suface envelope.

Analytical modelling, simulation and physical testing were used throughout the development process to determine runner sizing, plenum geometry and flow behaviour while evaluating their influence on engine performance.

Intake Manifold Design

Developed a square intake manifold configuration to promote even airflow distribution between cylinders and support volumetric efficiency targets.
Tuned runner length for 10,000 RPM using Helmholtz resonance wave theory.
Sized the plenum (1800cc) to support improved throttle response while accounting for the intake restrictor and packaging constraints.
Designed the runner inlets with a elliptical bell-mouth geometry to improve airflow into the intake runners.

CFD pressure analysis of Formula uOttawa intake manifold

ENGINEERING ANALYSIS

Simulation & Design Iteration

Performed steady-state CFD in Ansys Fluent to analyse flow separation and pressure recovery through the diffuser.
Performed transient CFD under maximum volumetric efficiency conditions to evaluate airflow distribution between the intake runners.
Compared pressure averages at the runner outlets to assess the distribution of airflow between cylinders.
Used Realis WAVE to iterate intake geometry and compare volumetric efficiency and torque across the engine operating range.
Used simulation results to guide successive design iterations and refine the intake geometry.

TESTING & VALIDATION

Validating the Intake Design

Extracted exhaust gas temperature data from each exhaust runner to evaluate cylinder-to-cylinder airflow distribution.
Measured approximately 4% discrepancy between the outer and middle cylinders, indicating improved airflow distribution across the engine.
Evaluated the volumetric efficiency tuning curve, which showed a significant increase around the target 10,000 RPM operating point.
Observed the largest effect in the volumetric efficiency curve at full throttle.
Developed testing methods to compare physical engine data with analytical and simulation results.

ACHIEVEMENTS

Results & Lessons Learned

Complete Design Process

Applied the full engineering design process from requirements definition and design through analysis, manufacturing and physical validation for prototype development.

Intake System Behaviour

Demonstrated the influence of intake system geometry on volumetric efficiency, airflow distribution and throttle response.

Testing & Validation

Developed testing methods to compare analytical and simulation results with physical engine data and validate the final intake design.

SKILLS

Technical Skills

Software

SolidWorks
Ansys Fluent
Realis WAVE

Engineering

Design Process
Fluid Mechanics
Simulation Analysis
Engine Airflow Analysis

Manufacturing & Validation

Additive Manufacturing
Packaging
Testing & Validation